WinGD X72 Operation Manual
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WinGD X72 Operation Manual

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Table of Contents

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Winterthur Gas & Diesel Ltd.
Winterthur Gas & Diesel AG
Winterthur Gas & Diesel S.A.
Schützenstrasse 3
P.O. Box 414, 8401
Winterthur, Switzerland
Operation Manual
Tel. +41 (0)52 264 8844
Fax +41 (0)52 264 8866
www.wingd.com
X72
Issue 001 2021-01

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Summary of Contents for WinGD X72

  • Page 1 Operation Manual Issue 001 2021-01 Winterthur Gas & Diesel Ltd. Schützenstrasse 3 Tel. +41 (0)52 264 8844 Winterthur Gas & Diesel AG P.O. Box 414, 8401 Fax +41 (0)52 264 8866 Winterthur Gas & Diesel S.A. Winterthur, Switzerland www.wingd.com...
  • Page 2 Information in this publication is subject to change without notice. NO LIABILITY, WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS INTENDED FOR INFORMATION PURPOSES ONLY. www.wingd.com...

  • Page 3: Table Of Contents

    Operation Manual Table of contents Introduction Operation Manual - change record......... . Preface.
  • Page 4 Operation Manual Design and function of the components Group 1 - Framework and bearings 4.1.1 Bedplate............4.1.2 Main bearing.
  • Page 5 Operation Manual 4.6.6 Water separator........... . . Group 7 - Cylinder lubrication and balancer 4.7.1 Cylinder lubrication.
  • Page 6 Operation Manual 5.3.28 LDU-20 page - USER PARAMETERS........5.3.29 LDU-20 page - LOG ENTRY DATA.
  • Page 7 Operation Manual Replace the filter element of the duplex filter....... . .410 Do a test of the exhaust waste valve.
  • Page 8 Operation Manual Page left intentionally blank - 8 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 9 Operation Manual List of tables Introduction Change record ..................... Data module codes (descriptive data) ............Data module codes (procedural data) ............List of abbreviations and acronyms ............. Design and function of the systems Operation limits of exhaust gas temperature after exhaust gas manifold ... HP SCR SYSTEM STATUS (MAIN PAGE) ..........
  • Page 10 Operation Manual 5-18 PILOT FUEL PRESSURE ................5-19 SCAVENGE AIR - EWG (optional) .............. 5-20 SOFTWARE INFO ..................5-21 IMO CRC INFO ................... 5-22 SOFTWARE TOOLS ................... 5-23 SYSTEM STATUS ..................5-24 SYSTEM SETTINGS ................... 5-25 TEMPERATURES ..................5-26 USER PARAMETERS ................. 5-27 LOG ENTRY DATA ..................
  • Page 11 Operation Manual 9-30 Fuel leakage flow from fuel rail items is too high (engine with FLV) .... 9-31 Fuel leakage flow from fuel rail items is too high (engine with ICU) .... 9-32 Fuel pressure in the fuel rail is too high (for X35/-B or X40/-B engine) ..9-33 Fuel pressure in the fuel rail is too low (for X35/-B or X40/-B engine) ..
  • Page 12 Operation Manual 10-10 Oil systems (XX2NNN, part 4) ..............10-11 Fuel system (XX34NN) ................10-12 Exhaust gas system (XX37NN) ..............10-13 Air systems (XX40NN to XX44NN) ............. 10-14 Miscellaneous items (XX45NN to XX52NN) ..........10-15 Failure messages ..................Schematic diagrams 12-1 Function code ....................
  • Page 13 Operation Manual List of illustrations Introduction Side view (generic) ..................Engine numbering (generic) ................ Design and function of the engine Pressure - volume diagram and schematic of the two-stroke diesel cycle .. Operating range ..................Tuning options ..................... Schematic diagram - Relation Speed/Power (FPP) ........Design and function of the systems Line codes for systems ................
  • Page 14 Operation Manual 3-33 LDU-20 page - LP SCR SYSTEM STATUS (MAIN PAGE) ......3-34 LDU-20 page - LP SCR SYSTEM OVERVIEW ........... 3-35 LDU-20 page - LP SCR INTERFACES ............3-36 LDU-20 page - LP SCR SOFTWARE INFO ..........3-37 LDU-20 page - LP SCR PAGE INDEX ............
  • Page 15 Operation Manual 4-34 Water separator (generic) ................4-35 Cylinder lubricating pump ................4-36 Effect of second order moments (M2v) of the engine ......... 4-37 iELBA - function ................... 4-38 iELBA - control cabinet ................4-39 Exhaust waste gate (generic) ..............4-40 Crank angle sensor unit on flywheel (example) ..........
  • Page 16 Operation Manual Operation of the engine Cooling water system with bypass cooling ..........Cooling water system without bypass cooling ..........Cooling water system with circulation ............Cylinder lubricant quantity ................Select: Prepare Tier III ................. Select: Tier III ....................Select: Tier II ....................Allowed load during cylinder cut out ............
  • Page 17 Operation Manual 1 Introduction Operation Manual - change record......... . Preface.

  • Page 18: Change Record

    AA00-0000-00AAA-003A-A Operation Manual Operation Manual - change record Operation Manual - change record Tab 1-1 Change record New issue 001, 2021-03 This is the initial issue of the newly structured operation manual. - 18 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 19 AA00-0000-00AAA-003A-A Operation Manual Operation Manual - change record Page left intentionally blank - 19 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 20 The data, instructions, graphics and illustrations etc in this manual are related to drawings from WinGD. These data relate to the date of issue of the manual (the year of the issue is shown on the title page and on the footer). All instructions, graphics and illustrations etc can change because of continuous new development and modifications.
  • Page 21 AA00-0000-00AAA-018A-A Operation Manual Preface Page left intentionally blank - 21 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 22: Technical Documentation Set

    AA00-0000-00AAA-018B-A Operation Manual Technical documentation set Technical documentation set Because of the continuous development of the engine, the technical documentation for the engine changes and is regularly updated. The change record shows all changes. Important data and changes are given directly to the customer in the service bulletins. To order technical documents, the data that follows is necessary: •...

  • Page 23: Technical Documentation Set

    External supplier documentation The documentation from external suppliers gives data about the parts of the engine that are not supplied by WinGD, such as turbocharger, automatic filter or damper. Most of this documentation also contains data about spare parts. 1.3.5...

  • Page 24: Data Module Codes (Descriptive Data)

    00 = applicable to all engines inde- acters [0-9] pendent of the number of cylinders; ## = applicable only to engines with that specific number of cylinders. #### WinGD design group number 4 numeric char- arbitrary 5551 acters [0-9] Used for sequential numbering of data...
  • Page 25 AA00-0000-00AAA-018D-A Operation Manual Data module codes (descriptive data) Page left intentionally blank - 25 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 26: Data Module Codes (Procedural Data)

    00 = applicable to all engines inde- acters [0-9] pendent of the number of cylinders; ## = applicable only to engines with that specific number of cylinders. #### WinGD design group number 4 numeric char- arbitrary 5556 acters [0-9] Used for sequential numbering for the...

  • Page 27: Data Module Codes (Procedural Data)

    AA00-0000-00AAA-018E-A Operation Manual Data module codes (procedural data) Code Description Length/type Property Example Shipdex item location code. A = infor- 1 alphabetic Shipdex specif- mation related to items installed on the character [A-D] product; B = information related to items installed on a major assembly re- moved from the product;...

  • Page 28: About This Book

    AA00-0000-00AAA-018C-A Operation Manual About this book About this book In the sections that follow you find the definitions of WinGD for this book. 1.6.1 Definitions for general text For general text in this book the definitions that follow are applicable: •...
  • Page 29 AA00-0000-00AAA-018C-A Operation Manual About this book 1.6.2 Warnings Warnings in procedures give data about a hazard. Warnings have the basic structure that follows: • Signal word The signal words that follow are applicable: ○ WARNING ○ CAUTION • Hazard The hazard data gives the dangerous situation. •...

  • Page 30: About The Engine

    Operation Manual About the engine About the engine In the sections that follow you find the definitions of WinGD for the engine. 1.7.1 Groups of components Each component of the engine has a four-digit material number. WinGD has divided these components related to the first digit of the number into 9 groups: •...

  • Page 31: Main Bearing

    AA00-0000-00AAA-018L-A Operation Manual About the engine 1.7.2 Engine sides and ends - names The sides and ends of the engine have the names and abbreviations that follow (refer to Figure 1-1: • DE - Driving End (end that has a flange to attach the propeller shaft) •...

  • Page 32: Engine Numbering (Generic)

    LEFT engine. Parts that are applicable for the two engines types (Standard and LEFT) have no mark. 1.7.4 Numbering of items WinGD uses the definitions for the numbering of items as follows (refer to Figure 1-2): • In axial direction the numbering starts from the flywheel.
  • Page 33 AA00-0000-00AAA-018L-A Operation Manual About the engine Page left intentionally blank - 33 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 34: List Of Abbreviations

    AA00-0000-00AAA-005A-A Operation Manual List of abbreviations List of abbreviations Tab 1-4 List of abbreviations and acronyms Short form Full form, meaning Angle Calculation Module crank Angle Determination Algorithm ahead alarm Alarm and Monitoring System as required astern ASTM American Society for Testing and Materials Bottom Dead Center Base Number BSEC...
  • Page 35 AA00-0000-00AAA-005A-A Operation Manual List of abbreviations Short form Full form, meaning Emission Control Area Engine Control Room Engine Control System eg or e.g. for example (exempli gratia) Exhaust Gas Recirculation ELBA ELectrical BAlancer Exhaust Side Engine Safety System FAME Fatty Acid Methyl Esters FAST Fuel Actuated Sacless Technology Flex Control Module...
  • Page 36 AA00-0000-00AAA-005A-A Operation Manual List of abbreviations Short form Full form, meaning Injection Control Unit ie or i.e. that is (id est) iELBA integrated ELectrical BAlancer iGPR integrated Gas Pressure Regulation International Maritime Organization Ind. Indenture Input Output Module International Standard Organization Japanese Industrial Standard Potassium hydroxide Local Display Unit...
  • Page 37 Top Dead Center UNIC UNIfied Controls Universal Serial Bus exhaust Valve Control Unit Variable Exhaust valve Closing Variable Exhaust valve Opening Variable Injection Timing WECS-9520 WinGD Engine Control System 9520 - 37 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 38 AA00-0000-00AAA-005A-A Operation Manual List of abbreviations Short form Full form, meaning Waste Heat Recovery WiCE WinGD Integrated Control Electronics WinGD Winterthur Gas & Diesel Ltd. Work Load Limit - 38 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 39: Design And Function Of The Engine

    Operation Manual 2 Design and function of the engine Short description of the engine..........Use of the engine.

  • Page 40: Short Description Of The Engine

    The engine control system (ECS) electronically controls all important engine functions (eg speed control, overspeed protection and fuel injection). The engine control can have different remote controls, which are related to the WinGD specifications from recommended manufacturers. - 40 - Issue 001 2021-01 Winterthur Gas &...

  • Page 41: Pressure - Volume Diagram And Schematic Of The Two-Stroke Diesel Cycle

    AA00-0000-00AAA-020A-A Operation Manual Short description of the engine 2.1.1 Cycle of a two-stroke diesel engine The sequences of a two-stroke diesel engine are as follows (refer to Figure 2-1): • Sequence 1 - 2 The piston moves up and thus compresses the scavenge air. This increases the temperature of the air above the self-ignition temperature of the fuel.

  • Page 42: Use Of The Engine

    AA00-0000-00AAA-020C-A Operation Manual Use of the engine Use of the engine 2.2.1 Intended use The engine is intended to drive a propeller of a vessel. The engine changes the chemical energy of the fuel to mechanical energy. The engine must only be used in the operating range as given in the data sheets, refer to chapter 11.
  • Page 43 AA00-0000-00AAA-020C-A Operation Manual Use of the engine 2.2.2 Incorrect use Incorrect use of the engine can result in personal injury and in damage to physical properties. Personal injury or damage to physical properties caused by incorrect use will be the responsibility of the operating company.

  • Page 44: Tuning Options

    AA00-0000-00AAA-020C-A Operation Manual Use of the engine 2.2.3 Tuning Related to the contract the engine has one of the tuning options that follow (refer to Figure 2-3): • Standard tuning The standard tuning gives a good fuel consumption over the full engine power range. •...
  • Page 45 AA00-0000-00AAA-020C-A Operation Manual Use of the engine Page left intentionally blank - 45 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 46: The Relation Between Engine And Propeller

    AA00-0000-00AAA-042B-A Operation Manual The relation between engine and propeller The relation between engine and propeller 2.3.1 General There is a specified relation between the propeller speed and the absorbed power in ships that have fixed pitch propellers. The relation is between the propeller and the speed at which it turns. The formula that follows (where P = power and n = speed) gives an approximate result, which is sufficient for conventional vessels: The graph from this formula is known as the propeller property.

  • Page 47: Schematic Diagram - Relation Speed/Power (Fpp)

    AA00-0000-00AAA-042B-A Operation Manual The relation between engine and propeller 2.3.2 Fixed pitch propeller (FPP) 2.3.2.1 Continuous service rating Point A (Figure 2-4) shows the power and speed of a ship that operates at contractual speed in calm seas with a new clean hull and propeller. A power / speed combination at point D is necessary for the same ship at the same speed during service conditions with aged hull and average weather.
  • Page 48 AA00-0000-00AAA-042B-A Operation Manual The relation between engine and propeller • Line 2 is the overload limit. This is a constant MEP line from 100% power and 93.8% speed to 110% power and 103.2% speed. 103.2% speed is the intersection point between the nominal propeller property and 110% power.
  • Page 49 AA00-0000-00AAA-042B-A Operation Manual The relation between engine and propeller Page left intentionally blank - 49 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 50: Safety

    AA00-0000-00AAA-012A-A Operation Manual Safety precautions and safety guidelines Safety 2.4.1 Safety precautions and safety guidelines 2.4.1.1 General safety precautions Use the data given below as a guide to the personnel. • Lighting Make sure that there is good permanent lighting in the engine room. Have a sufficient number of hand lamps available at different locations in the engine room.
  • Page 51 AA00-0000-00AAA-012A-A Operation Manual Safety precautions and safety guidelines 2.4.1.2 General safety guidelines If you do work at or near the engine, obey the guidelines that follow to prevent risks of harm or damage to personal, to equipment, or to environment. •...
  • Page 52 AA00-0000-00AAA-012A-A Operation Manual Safety precautions and safety guidelines • Guidelines for hot work: General Hot work means any work requiring the use of electric arc or gas welding equipment, cutting burner equipment or other forms of naked flame, as well as heating or spark generating tools, regardless of where it is carried out on board.
  • Page 53 AA00-0000-00AAA-012A-A Operation Manual Safety precautions and safety guidelines Page left intentionally blank - 53 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 54: Contamination And Fire In The Scavenge Air Spaces

    AA00-0000-00AAA-012B-A Operation Manual Contamination and fire in the scavenge air spaces 2.4.2 Contamination and fire in the scavenge air spaces 2.4.2.1 Causes of contamination The primary cause of contamination is when combustion materials are blown between the piston and cylinder into the scavenge air spaces (blow-by). The contamination will be more if the fuel is not fully burned, which causes exhaust smoke.
  • Page 55 AA00-0000-00AAA-012B-A Operation Manual Contamination and fire in the scavenge air spaces 2.4.2.2 Causes of fire The causes of fires are as follows: • If sealing rings of the piston rod gland are defective, system oil and cylinder oil will collect in the piston underside.

  • Page 56: Fire-Fighting In The Scavenge Air Space

    AA00-0000-00AAA-140B-A Operation Manual Fire-fighting in the scavenge air space 2.4.3 Fire-fighting in the scavenge air space Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 57 AA00-0000-00AAA-140B-A Operation Manual Fire-fighting in the scavenge air space PROCEDURE If you think there is no fire, do the steps as follows: Decrease the engine power. Cut out the injection of the related cylinder. Increase the feed rate of the lubricating oil in the related cylinder to the maximum, although there is high temperature in the related cylinder.

  • Page 58: Explosions In The Crankcase

    AA00-0000-00AAA-012C-A Operation Manual Explosions in the crankcase 2.4.4 Explosions in the crankcase Examples of explosions in the crankcase of diesel engines have shown that they can only occur in special conditions, and thus do not occur frequently. The cause of crankcase explosions is oil mist. Oil mist comes from components that have become unusually hot.
  • Page 59 AA00-0000-00AAA-012C-A Operation Manual Explosions in the crankcase Page left intentionally blank - 59 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 60: Prevent Explosions In The Crankcase

    AA00-0000-00AAA-012D-A Operation Manual Prevent explosions in the crankcase 2.4.5 Prevent explosions in the crankcase Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description Specialization...
  • Page 61 AA00-0000-00AAA-012D-A Operation Manual Prevent explosions in the crankcase PROCEDURE If an oil mist detector activates an alarm, do as follows: Decrease immediately the engine speed (power). Stop the engine if possible. Let the engine temperature decrease for a minimum of 20 minutes. Find the cause and repair the fault.

  • Page 62: Access To Engine Spaces

    AA00-0000-00AAA-012E-A Operation Manual Access to engine spaces 2.4.6 Access to engine spaces Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description Specialization Engine crew...
  • Page 63 AA00-0000-00AAA-012E-A Operation Manual Access to engine spaces PROCEDURE Make sure that there is always a safety person on the outer side of the engine. Wear the correct safety equipment. For a DF engine, obey the safety rules for natural gas, refer to section [section not applicable for this engine].
  • Page 64 AA00-0000-00AAA-012E-A Operation Manual Access to engine spaces Page left intentionally blank - 64 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 65: Design And Function Of The Systems

    Operation Manual 3 Design and function of the systems General for systems............Cooling water system.

  • Page 66: General For Systems

    AA00-0000-00AAA-043U-A Operation Manual General for systems General for systems In the chapters that follow you can find a short description of the systems of the engine. The descriptions and figures are generic and simplified. You can find an overview of the used line codes in Figure 3-1.
  • Page 67 AA00-0000-00AAA-043U-A Operation Manual General for systems Page left intentionally blank - 67 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 68: Cooling Water System

    AA00-0000-00AAA-043A-A Operation Manual Cooling water system Cooling water system The cooling water system supplies the items that follow with cooling water: • Cylinder liner • Cylinder cover • Exhaust valve cages • Scavenge air cooler (SAC). For the schematic diagrams, refer to section 12.1 Schematic diagrams - general.

  • Page 69: Cooling Water System (Generic And Simplified)

    AA00-0000-00AAA-043A-A Operation Manual Cooling water system Fig 3-2 Cooling water system (generic and simplified) Cyl. 1 Cyl. n Legend Automatic venting unit Drain valve Shut-off valve cooling water outlet Orifice Shut-off valve, if supply 02 is installed Optional vent valve (usually closed) Shut-off valve, if supply 02 is not installed Vent valve (usually open) Shut-off valve...

  • Page 70: Wash-Water System

    AA00-0000-00AAA-043P-A Operation Manual Wash-water system Wash-water system The wash-water system supplies the scavenge air cooler (SAC) with wash-water. This lets you wash the SAC, refer to 8.6 Clean the scavenge air cooler during operation. To regularly wash the SAC increases the service life of the cooler and keeps the performance in the specified range.
  • Page 71 AA00-0000-00AAA-043P-A Operation Manual Wash-water system Fig 3-3 Wash-water system (generic and simplified) 11 12 Legend Wash-water tank Cyclone separator Scavenge air cooler (SAC) Turbocharger Auxiliary blower - 71 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 72: System Oil System

    AA00-0000-00AAA-043B-A Operation Manual System oil system System oil system The system oil system supplies the items that follow with system oil: • Bearings • Gear wheels • Vibration dampers • Pistons • Crosshead assemblies • iELBA (optional) • Other running parts •...

  • Page 73: Thrust Bearing

    AA00-0000-00AAA-043B-A Operation Manual System oil system Fig 3-4 System oil system (generic and simplified) PLANT ENGINE ENGINE PLANT 23 22 22 23 Legend Turbocharger Crosshead iELBA (optional) Thrust bearing Torsional vibration damper (optional) Oil sample valve Axial vibration damper Lever Main bearing Supply pipe to servo oil system Crank bearing...

  • Page 74: Servo Oil System

    AA00-0000-00AAA-043Q-A Operation Manual Servo oil system Servo oil system The servo oil system supplies the items that follow with servo oil: • Exhaust valve control units (VCU) • Cylinder lubricating pumps • Injection control units, if applicable. For the schematic diagrams, refer to section 12.1 Schematic diagrams - general.
  • Page 75 AA00-0000-00AAA-043Q-A Operation Manual Servo oil system Page left intentionally blank - 75 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 76: Cylinder Oil System

    AA00-0000-00AAA-043R-A Operation Manual Cylinder oil system Cylinder oil system The cylinder oil system supplies cylinder oil onto the cylinder liners. The engine control system (ECS) controls the adjustable load-related supply rate of cylinder oil to each lubrication point. The engine has an automatic pre-lubrication sequence. At each engine start the ECS automatically starts this sequence.
  • Page 77 AA00-0000-00AAA-043R-A Operation Manual Cylinder oil system Page left intentionally blank - 77 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 78: Starting Air System

    AA00-0000-00AAA-043C-A Operation Manual Starting air system Starting air system The starting air system turns the crankshaft before the usual combustion cycle of the engine is started. For the schematic diagrams, refer to section 12.1 Schematic diagrams - general. The starting air system has the engine connections as interface to the plant as follows (in Figure marked with a circle): •...

  • Page 79: Starting Air System (Generic And Simplified)

    AA00-0000-00AAA-043C-A Operation Manual Starting air system Fig 3-5 Starting air system (generic and simplified) Cyl. 1 Cyl. n Legend Solenoid valve Disengaging device turning gear Flame arrestor Starting air supply pipe Safety valve Valve unit for start E Drain valve Starting air shut-off valve Control air supply Collector for leakage oil from the air spring...

  • Page 80: Scavenge Air System

    AA00-0000-00AAA-043S-A Operation Manual Scavenge air system Scavenge air system The scavenge air system replaces the exhaust gas in the cylinder with fresh air. For the schematic diagrams, refer to section 12.1 Schematic diagrams - general. The scavenge air comes in from the outside through a duct or from the engine room. The scavenge air enters at the silencer of the turbocharger.
  • Page 81 AA00-0000-00AAA-043S-A Operation Manual Scavenge air system Fig 3-6 Scavenge air system 00148 Legend Exhaust gas manifold Drains Exhaust gas outlet Auxiliary blower Scavenge air inlet Piston underside Turbine Piston Compressor Scavenge air receiver Scavenge air cooler Cylinder liner Water separator Exhaust valve Charging unit - 81 -...

  • Page 82: Control Air System

    AA00-0000-00AAA-043T-A Operation Manual Control air system Control air system The control air system supplies the air spring of the exhaust valves and the starting air system with control air. For the schematic diagrams, refer to section 12.1 Schematic diagrams - general.
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  • Page 84: Exhaust Gas System

    AA00-0000-00AAA-043D-A Operation Manual Exhaust gas system 3.10 Exhaust gas system The exhaust gas system collects the exhaust gas of the cylinders in a manifold. The remaining energy of the exhaust gas is used to operate the turbine of the turbocharger. For the schematic diagrams, refer to section 12.1 Schematic diagrams - general.
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  • Page 86: Fuel System

    AA00-0000-00AAA-043E-A Operation Manual Fuel system 3.11 Fuel system The fuel system supplies the injection valves of the cylinders with the applicable quantity of fuel. For the schematic diagrams, refer to section 12.1 Schematic diagrams - general. The fuel system has the engine connections as interface to the plant as follows (in Figure 3-7 Figure 3-8 marked with a circle):...
  • Page 87 AA00-0000-00AAA-043E-A Operation Manual Fuel system • Non-return valve The non-return valves prevent fuel flow back from the fuel rail to the fuel pumps (eg if a fuel pump has no delivery, or a fuel pipe is defective). • Pressure control valve The pressure control valve (001) has different functions to control the flow and the pressure in the fuel rail.

  • Page 88: Fuel Pump

    AA00-0000-00AAA-043E-A Operation Manual Fuel system Fig 3-7 Fuel system with FLV (generic and simplified) Cyl. 1 Cyl. n Legend Pressure control valve Injection valve Relief valve Supply unit Flow limiting valve (FLV) Fuel pump Fuel rail Pressure retaining valve Rail unit - 88 - Issue 001 2021-01 Winterthur Gas &...

  • Page 89: Pressure Control Valve

    AA00-0000-00AAA-043E-A Operation Manual Fuel system Fig 3-8 Fuel system with ICU (generic and simplified) Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 Cyl. n 60 50 49 Legend Pressure control valve Injection valve Relief valve Supply unit Injection control unit (ICU) Fuel pump Fuel rail Pressure retaining valve...

  • Page 90: Hp Selective Catalytic Reduction System

    The HP SCR system is installed between the exhaust gas manifold and the turbocharger. The system design and the supply of components is divided between the HP SCR system supplier, the shipyard and WinGD/engine builder. The HP SCR system adds an urea water solution as reducing agent to the exhaust gas flow.

  • Page 91: Hp Scr System - Layout

    AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system • Venting/sealing unit The venting/sealing unit supplies compressed air into the exhaust gas pipes for the functions that follow: ○ Blow out the exhaust gas from the reactor and the pipes after stop of the HP SCR system ○...

  • Page 92: Operation Limits Of Exhaust Gas Temperature After Exhaust Gas Manifold

    The engine control system (ECS) calculates this value related to the engine load and to the exhaust gas pressure. NOTE: WinGD recommends to do a test of the valves regularly during engine stop, refer to Figure 3-23. 3.12.2 Operation modes The HP SCR system has the operation modes that follow.

  • Page 93: Hp Scr System - Emergency Bypass

    AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system 3.12.2.1 HP SCR system - emergency bypass In this operation mode, the HP SCR system is bypassed. The HP SCR control system opens the valve V3 quickly. The engine operates in Tier II mode. If necessary, you can start this operation mode manually.

  • Page 94: Hp Scr System - Change From Tier Iii To Bypass

    AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system 3.12.2.2 HP SCR system - bypass In this operation mode, the HP SCR system is bypassed. The engine operates in Tier II mode. Urea solution is not injected. If you change from Tier III mode to bypass mode, the HP SCR control system changes the valve conditions and starts the preservation sequence.

  • Page 95: Hp Scr System - Purging And Venting

    AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system Legend Mixing duct Venting/sealing unit Reactor Urea solution supply unit Turbine of turbocharger Soot blowing unit Engine Fig 3-12 HP SCR system - purging and venting Legend Mixing duct Venting/sealing unit Reactor Urea solution supply unit Turbine of turbocharger Soot blowing unit...
  • Page 96 AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system Fig 3-13 HP SCR system - emergency bypass Legend Mixing duct Venting/sealing unit Reactor Urea solution supply unit Turbine of turbocharger Soot blowing unit Engine - 96 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 97: Hp Scr System - Preparation

    AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system 3.12.2.3 HP SCR system - preparation In this operation mode, exhaust gas causes the temperature of the HP SCR reactor to slowly increase. The engine operates in Tier II mode. Urea solution is not injected. The valves have the conditions that follow: •...

  • Page 98: Hp Scr System - Tier Iii

    AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system 3.12.2.4 HP SCR system - Tier III In this operation mode, the HP SCR system is set to ON. The engine operates in Tier III mode. Urea solution is injected. The valves have the conditions that follow: •...

  • Page 99: Hp Scr

    AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system 3.12.2.5 HP SCR system - at engine stop If you stop the engine in Tier III mode, the HP SCR system changes to bypass mode after some time. Related to the condition the venting/sealing unit starts for some minutes, refer to Para 3.12.2.2.
  • Page 100 AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system 3.12.3.1 Control box E48 The control box E48 is installed in the engine room and has switches and visual indicators. Fig 3-17 Control box E48 00561 Legend SCR bypass switch Option SPC - Indication - SPC running Option SPC - SPC bypass switch Indication - urea injection Indication - minor failure...
  • Page 101 AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system 3.12.3.2 Control box E49 The control box E49 is installed in the engine control room and has switches below the LDU-20. Fig 3-18 Control box E49 00562 Legend LDU-20 Option SPC - SPC bypass switch SCR bypass switch - 101 - Issue 001 2021-01...

  • Page 102: Control Box E50

    AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system 3.12.3.3 Control box E50 The control box E50 is installed on the engine and has switches below the LDU-20. Fig 3-19 Control box E50 00563 Legend LDU-20 SCR bypass switch Option SPC - SPC bypass switch 3.12.3.4 Messages of the HP SCR control system The HP SCR control system gives three messages to the alarm and monitoring system (AMS).

  • Page 103: Hp Scr System Status (Main Page)

    AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system Fig 3-20 LDU-20 page - HP SCR SYSTEM STATUS (MAIN PAGE) Tab 3-2 HP SCR SYSTEM STATUS (MAIN PAGE) Item Function Effect OVERVIEW button Opens the SCR system overview page INTERFACES button Opens the interfaces page MAN CTRL button Opens the manual control page...

  • Page 104: Hp Scr System Overview

    AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system Fig 3-21 LDU-20 page - HP SCR SYSTEM OVERVIEW Tab 3-3 HP SCR SYSTEM OVERVIEW Item Function Effect INTERFACES button Opens the interfaces page MAN CTRL button Opens the manual control page INDEX button Opens the index page SCREENSHOT button...

  • Page 105: Hp Scr Interfaces

    AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system Fig 3-22 LDU-20 page - HP SCR INTERFACES Tab 3-4 HP SCR INTERFACES Item Function Effect OVERVIEW button Opens the SCR system overview page MAN CTRL button Opens the manual control page INDEX button Opens the index page SCREENSHOT button...

  • Page 106: Hp Scr Manual Valve Control

    AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system Fig 3-23 LDU-20 page - HP SCR MANUAL VALVE CONTROL Tab 3-5 HP SCR MANUAL VALVE CONTROL Item Function Effect OVERVIEW button Opens the SCR system overview page INTERFACES button Opens the interfaces page INDEX button Opens the index page SCREENSHOT button...

  • Page 107: Hp Scr Software Info

    AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system Item Function Effect Button and indication Gives manual control of the related valve and shows the sta- tus (serviceable only if the manual mode is permitted) Status indication Shows the engine status Fig 3-24 LDU-20 page - HP SCR SOFTWARE INFO Tab 3-6...

  • Page 108: Page - Hp Scr

    AA00-9270-00AAA-043A-A Operation Manual HP Selective catalytic reduction system Item Function Effect DB number Shows identification number of the installation Fig 3-25 LDU-20 page - HP SCR PAGE INDEX Tab 3-7 HP SCR PAGE INDEX Item Function Effect INDEX button Opens the index page SCREENSHOT button Makes a screenshot of the current screen RCS CTRL ON button...
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  • Page 110: Lp Selective Catalytic Reduction System

    The LP SCR system is installed after the turbocharger. The system design and the supply of components is divided between the LP SCR system supplier, the shipyard and WinGD/engine builder. The LP SCR system adds a urea water solution to the exhaust gas flow. Chemical reactions change nitrogen oxides to molecular nitrogen and water, which are not dangerous.

  • Page 111: Lp Scr Temperature Controlled (Example)

    AA00-9270-00AAA-043B-A Operation Manual LP Selective catalytic reduction system • Valves The valves in the LP SCR system are used for the different operation modes. The LP SCR system has the valves that follow: ○ V1 - reactor inlet valve ○ V2 - reactor outlet valve ○...

  • Page 112: Lp Scr Bypass Rate Controlled (Example)

    AA00-9270-00AAA-043B-A Operation Manual LP Selective catalytic reduction system Fig 3-27 LP SCR bypass rate controlled (example) 002 003 Legend Engine Burner Urea dosing unit LP SCR reactor Decomposition unit Turbocharger 3.13.2 Operation modes The LP SCR system can be operated if the exhaust gas temperature is in the permitted limits. These limits are adjusted during commissioning.
  • Page 113 AA00-9270-00AAA-043B-A Operation Manual LP Selective catalytic reduction system 3.13.2.2 LP SCR system - preparation In this operation mode, exhaust gas causes the temperature of the LP SCR reactor to slowly increase. Urea solution is not injected. The valves have the conditions that follow: •...

  • Page 114: Lp Scr Control System Layout

    LP Selective catalytic reduction system 3.13.3 LP SCR control system The main tasks of the WinGD control system for the LP SCR system are as follows: • Calculate the setpoint position for the turbine bypass valve (V4) to control the exhaust gas temperature.

  • Page 115: Lp Scr System - Principal Control Configuration

    AA00-9270-00AAA-043B-A Operation Manual LP Selective catalytic reduction system Fig 3-29 LP SCR system - principal control configuration Engine room Signals External main control panel (E73) 3.13.3.1 Messages of the LP SCR control system The LP SCR control system gives three messages to the alarm and monitoring system (AMS). The messages are as follows: •...

  • Page 116: Control Box E70 With Option Spc

    AA00-9270-00AAA-043B-A Operation Manual LP Selective catalytic reduction system 3.13.3.2 Control box E70 The control box E70 is installed on the engine and has switches and visual indicators. Fig 3-30 Control box E70 with option SPC Legend SCR bypass switch Indication (orange) - SPC bypass Indication (red) - SCR failure Indication (green) - SPC running Indication (orange) - SCR bypass...

  • Page 117: Control Box E71 With Option Spc

    AA00-9270-00AAA-043B-A Operation Manual LP Selective catalytic reduction system 3.13.3.3 Control box E71 The control box E71 is installed on the engine or in the engine room and has switches below the LDU-20. Fig 3-31 Control box E71 with option SPC Legend LDU-20 SCR bypass switch...

  • Page 118: Control Boxes E72 And E73

    AA00-9270-00AAA-043B-A Operation Manual LP Selective catalytic reduction system 3.13.3.4 Control box E72 or E73 The control box E72 (without SPC) or E73 (with SPC) is installed in the engine control room and has switches below the LDU-20. Fig 3-32 Control boxes E72 and E73 Legend LDU-20 SPC bypass switch...

  • Page 119: Lp Scr System Status (Main Page)

    AA00-9270-00AAA-043B-A Operation Manual LP Selective catalytic reduction system 3.13.4 LDU-20 pages The LDU-20 panel has the pages that follow (examples). Fig 3-33 LDU-20 page - LP SCR SYSTEM STATUS (MAIN PAGE) Tab 3-8 LP SCR SYSTEM STATUS (MAIN PAGE) Item Function Effect OVERVIEW button...

  • Page 120: Lp Scr System Overview

    AA00-9270-00AAA-043B-A Operation Manual LP Selective catalytic reduction system Fig 3-34 LDU-20 page - LP SCR SYSTEM OVERVIEW Tab 3-9 LP SCR SYSTEM OVERVIEW Item Function Effect INTERFACES button Opens the interfaces page INDEX button Opens the index page SCREENSHOT button Makes a screenshot of the current screen RCS CTRL OFF button Gets control from the remote control system (if button is ac-...

  • Page 121: Lp Scr Interfaces

    AA00-9270-00AAA-043B-A Operation Manual LP Selective catalytic reduction system Fig 3-35 LDU-20 page - LP SCR INTERFACES Tab 3-10 LP SCR INTERFACES Item Function Effect OVERVIEW button Opens the SCR system overview page INDEX button Opens the index page SCREENSHOT button Makes a screenshot of the current screen RCS CTRL OFF button Gets control from the remote control system (if button is ac-...

  • Page 122: Lp Scr Software Info

    AA00-9270-00AAA-043B-A Operation Manual LP Selective catalytic reduction system Fig 3-36 LDU-20 page - LP SCR SOFTWARE INFO Tab 3-11 LP SCR SOFTWARE INFO Item Function Effect INDEX button Opens the index page SCREENSHOT button Makes a screenshot of the current screen RCS CTRL ON button Gets control from the remote control system (if button is ac- tive)

  • Page 123: Lp Scr Page Index

    AA00-9270-00AAA-043B-A Operation Manual LP Selective catalytic reduction system Fig 3-37 LDU-20 page - LP SCR PAGE INDEX Tab 3-12 LP SCR PAGE INDEX Item Function Effect INDEX button Opens the index page SCREENSHOT button Makes a screenshot of the current screen RCS CTRL ON button Gets control from the remote control system (if button is ac- tive)

  • Page 124: Steam Production Control System

    AA00-9270-00AAA-043C-A Operation Manual Steam production control system 3.14 Steam production control system The steam production control system (SPC) supplies the steam production of the ship with exhaust gas, which has a higher temperature. SPC is an optional system. NOTE: The engine obeys the IMO NOx limits, with and without steam production. Fig 3-38 Example of SPC Legend...

  • Page 125: Page - Steam Production Control

    AA00-9270-00AAA-043C-A Operation Manual Steam production control system Fig 3-39 LDU-20 page - STEAM PRODUCTION CONTROL Tab 3-13 STEAM PRODUCTION CONTROL (SPC) Item Function Effect ON/OFF button Starts or stops the SPC system INDEX button Opens the index page SCREENSHOT button Makes a screen shot of the current screen RCS CTRL ON button Gets control from the remote control system (if button is ac-...
  • Page 126 AA00-9270-00AAA-043C-A Operation Manual Steam production control system Item Function Effect PressCtrl mode 1 button Starts the PressCtrl mode 1 This mode is applicable only, if the steam pressure signal from the steam plant is correct. SPC compares the setpoint and the actual steam pressure. If there is a difference, it opens or closes the EWG to change the steam pressure.

  • Page 127: Ldu For The Steam Boost Mode

    AA00-9270-00AAA-043C-A Operation Manual Steam production control system 3.14.4 LDU screen for steam boost mode Fig 3-40 LDU for the steam boost mode - 127 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 128 AA00-9270-00AAA-043C-A Operation Manual Steam production control system 3.14.5 Activate the steam boost mode Before activating the steam boost mode, make sure the LDU-Screen (Figure 3-40) shows the following: • Firing Pressure Gas Mode indicates (5) “OK”. • Servo Oil (6) indicates “OK”. •...
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  • Page 130: Synchro Phasing System

    AA00-0000-00AAA-043V-A Operation Manual Synchro phasing system 3.15 Synchro phasing system The synchro phasing system is an option for twin propulsion. The vibrations of both engines or the propellers can lead to disturbing vibration resonances. The synchro phasing system reduces or compensates the disturbing vibrations in the ship hull and superstructure by syncing the phase angle between the two crankshafts.

  • Page 131: Page For Operation Mode "Control On

    AA00-0000-00AAA-043V-A Operation Manual Synchro phasing system 3.15.1.2 Worksteps Fig 3-41 LDU-20 page for operation mode "Control On" On the LDU-Screen, click the “Control ON” panel until the LED left to it lights up. On the right next to the LDU-Screen, turn the wheel to adjust the setpoint. Once you reach the desired setpoint (see figure) press the wheel to confirm.

  • Page 132: Page For Adjusting The Set Point

    AA00-0000-00AAA-043V-A Operation Manual Synchro phasing system Fig 3-42 LDU-20 page for adjusting the set point After step 3, the “Setpoint Reached” LED lights up at the bottom left of the LDU-Screen. This means, that the phase angle will now start converging to the desired setpoint. The vibration reduction is now active.

  • Page 133: Page For Operation Mode "Off

    AA00-0000-00AAA-043V-A Operation Manual Synchro phasing system 3.15.2 Switch off the synchro phasing system Fig 3-43 LDU-20 page for operation mode "Off" On the LDU-Screen, press the “Off” panel until the LED left to it lights up. - 133 - Issue 001 2021-01 Winterthur Gas &...

  • Page 134: Page For Operation Mode "Estimate Only

    AA00-0000-00AAA-043V-A Operation Manual Synchro phasing system 3.15.3 Examine the synchro phasing system Fig 3-44 LDU-20 page for operation mode "Estimate Only" On the LDU-Screen, press the panel “Estimate Only” until the LED left to it lights up. On the LDU-Screen, press the tab “CA States” or keep the rotary know pressed down. After step 2, the page “Crank Angle and Speed States”...

  • Page 135: Page For Crank Angle And Speed States

    AA00-0000-00AAA-043V-A Operation Manual Synchro phasing system Fig 3-45 LDU-20 page for crank angle and speed states - 135 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
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  • Page 137: Flow Limiting Valve

    Operation Manual 4 Design and function of the components Group 1 - Framework and bearings 4.1.1 Bedplate............4.1.2 Main bearing.

  • Page 138: Auxiliary Blower

    Operation Manual 4.6.3 Auxiliary blower........... . . 4.6.4 Auxiliary blower switch box.
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  • Page 140: Group 1 - Framework And Bearings

    AA00-1115-00AAA-043A-A Operation Manual Bedplate Group 1 - Framework and bearings 4.1.1 Bedplate The bedplate is the basic structure of the engine. The bearing girders (001, Figure 4-1) are attached in the bedplate and hold the crankshaft. The bottom part of the bedplate is the crankcase and collects lubricating oil. This oil flows back to the oil supply system through oil drains (002).
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  • Page 142: Main

    AA00-1132-00AAA-043A-A Operation Manual Main bearing 4.1.2 Main bearing The main bearings hold the crankshaft (007, Figure 4-2) and transmit the forces through the bearing girders (008) into the bedplate. The bottom bearing shell (006) is installed in the bearing girder (008) of the bedplate and the top bearing shell (004) in the bearing cover (003).
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  • Page 144: Thrust Bearing

    AA00-1203-00AAA-043A-A Operation Manual Thrust bearing 4.1.3 Thrust bearing The thrust bearing is installed on the crankshaft at the driving end of the engine. The thrust bearing flange (014, Figure 4-3) transmits the axial thrust from the propeller through the thrust pads into the bedplate: •...

  • Page 145: Thrust Bearing (Generic)

    AA00-1203-00AAA-043A-A Operation Manual Thrust bearing Fig 4-3 Thrust bearing (generic) Legend Column Crankshaft Oil pipe 2-part oil baffle Nozzle Flywheel Arbor support Bedplate Bedplate Thrust pad (engine side) Thrust pad (driving end) Thrust bearing flange Bearing cover Column Crankshaft gear wheel - 145 - Issue 001 2021-01 Winterthur Gas &...

  • Page 146: Monoblock Column

    AA00-1406-00AAA-043A-A Operation Manual Monoblock column 4.1.4 Monoblock column The monoblock column is the middle part of the engine. The monoblock column is installed on the bedplate and holds the cylinders. On the exhaust side (ES) the monoblock column has one relief valve (001, Figure 4-4) per cylinder.
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  • Page 148: Tie Rod

    AA00-1903-00AAA-043A-A Operation Manual Tie rod 4.1.5 Tie rod The tie rods (004, Figure 4-5) keep the cylinder block (002), column (003) and bedplate (005) together at four locations around each cylinder. Fig 4-5 Tie rod (generic) Legend Protection cover Tie rod Cylinder block Bedplate Column...
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  • Page 150: Cylinder - Cooling Water Outlet (Generic)

    AA00-2124-00AAA-043A-A Operation Manual Cylinder liner Group 2 - Cylinder 4.2.1 Cylinder liner The cylinder liner is one of the primary parts of the engine. The cylinder liner is on the cylinder jacket and holds the cylinder cover and the water guide jackets. The nuts and the elastic bolts hold these parts together.
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  • Page 152: Lubricating Quill

    AA00-2138-00AAA-043A-A Operation Manual Lubricating quill 4.2.2 Lubricating quill The lubricating quills spray oil onto the cylinder liner wall. The lubricating quills are installed on the circumference of the cylinder liner. The cylinder lubricating pump supplies a specified quantity of cylinder oil at high pressure through the cylinder oil inlet (006, Figure 4-7) into the lubricating quills.
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  • Page 154: Piston Rod Gland

    AA00-2303-00AAA-043A-A Operation Manual Piston rod gland 4.2.3 Piston rod gland The piston rod gland keeps the dirty cylinder oil in the scavenge space and thus prevents contamination of the bearing oil in the crankcase. Also, the piston rod gland seals the scavenge air from the crankcase.
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  • Page 156: Direct Controlled Injection Valve

    AA00-2722-00AAA-043A-A Operation Manual Direct controlled injection valve 4.2.4 Direct controlled injection valve The injection valves are installed in the cylinder cover of each cylinder. The injection valves spray the fuel into the combustion chamber. The ECS controls the pilot valve of the injection valves indirectly through the solenoid valve.
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  • Page 158: Starting Valve

    AA00-2728-00AAA-043A-A Operation Manual Starting valve 4.2.5 Starting valve The starting valve in each cylinder cover supplies pressurized air into the combustion chamber in the two situations that follow: • To start the engine before combustion starts • To decrease the engine speed when combustion has stopped. The ECS and the cylinder control modules (CCM-20) control and monitor the starting valves.
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  • Page 160: Exhaust Valve (Generic)

    AA00-2751-00AAA-043A-A Operation Manual Exhaust valve 4.2.6 Exhaust valve The exhaust valve in each cylinder cover releases the exhaust gas of the combustion into the exhaust gas manifold. The hydraulic oil pressure from the exhaust valve control unit (VCU) opens the exhaust valve. The pneumatic pressure of the air spring closes the exhaust valve. Fig 4-10 Exhaust valve (generic) Legend...
  • Page 161 AA00-2751-00AAA-043A-A Operation Manual Exhaust valve • Air spring When the exhaust valve is closed, compressed air flows through an air inlet connection into the air spring (011). When the exhaust valve opens, this air is compressed to a higher value. When the hydraulic oil pressure releases, the compressed air expands and thus closes the exhaust valve.

  • Page 162: Group 3 - Crankshaft, Connecting Rod And Piston

    AA00-3103-00AAA-043A-A Operation Manual Crankshaft Group 3 - Crankshaft, connecting rod and piston 4.3.1 Crankshaft The crankshaft turns as it gets the power from the pistons. The crankshaft transmits the power to the attached propeller shaft of the ship. Main bearings on the two sides of each crank (002, Figure 4-11) hold the crankshaft in position.
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  • Page 164: Torsional Vibration Damper

    AA00-3130-00AAA-043A-A Operation Manual Torsional vibration damper 4.3.2 Torsional vibration damper The torsional vibration damper decreases the torsional vibrations in the shafting system and in other components of the engine. If a torsional vibration damper is necessary for the engine, one of the two damper types that follow can be used.
  • Page 165 AA00-3130-00AAA-043A-A Operation Manual Torsional vibration damper 4.3.2.1 Steel spring damper A steel spring damper (Figure 4-12) is a tuned torsional vibration damper. It consists of two main parts: • The inner part (inner star (005) and spring pack (004)) is attached to the crankshaft flange at the free end.
  • Page 166 AA00-3130-00AAA-043A-A Operation Manual Torsional vibration damper 4.3.2.2 Viscous damper A viscous damper (Figure 4-13) is a tuned torsional vibration damper. It consists of two main parts: • The housing (002) is fully sealed and is attached to the crankshaft flange at the free end. •...
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  • Page 168: Axial Vibration Damper (Generic)

    AA00-3140-00AAA-043A-A Operation Manual Axial vibration damper 4.3.3 Axial vibration damper The axial vibration damper decreases the axial vibrations of the crankshaft. The axial vibration damper is attached with bolts to the last bearing girder at the free end of the engine. The axial vibration damper includes a top cylinder half (002, Figure 4-14) and a bottom cylinder...
  • Page 169 AA00-3140-00AAA-043A-A Operation Manual Axial vibration damper 4.3.3.1 Function Oil flows from the oil inlet (012) through the top cylinder half (002) into the two annular spaces (003). When the crankshaft (004) moves in an axial direction, the pressure of the oil in the compressed annular space (003) increases.

  • Page 170: Turning Gear

    AA00-3206-00AAA-043A-A Operation Manual Turning gear 4.3.4 Turning gear The turning gear slowly turns the crankshaft and thus moves the pistons, if the pinion (002, Figure 4-16) is engaged on the flywheel (003). The electric motor (001) turns the pinion (002) and is attached on the driving end of the engine.
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  • Page 172: Connecting Rod And Connecting Rod Bearing (Generic)

    AA00-3303-00AAA-043A-A Operation Manual Connecting rod and connecting rod bearing 4.3.5 Connecting rod and connecting rod bearing The connecting rod connects the crosshead with the crankshaft and converts the linear movement of the piston into a circular movement of the crankshaft. The bearing shells are installed on the connecting rod for the bottom end bearing and the top end bearing.
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  • Page 174: Crosshead And Guide Shoe

    AA00-3326-00AAA-043A-A Operation Manual Crosshead and guide shoe 4.3.6 Crosshead and guide shoe The crosshead guides the piston rod (009, Figure 4-18) and absorbs the lateral forces that come from the connecting rod (005). The piston rod (009) is attached to the compression shim (007) and the crosshead pin (006) with screws.
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  • Page 176: Piston

    AA00-3403-00AAA-043A-A Operation Manual Piston 4.3.7 Piston The piston moves in each cylinder. The piston rings seal the combustion chamber. The piston transmits the force from the gas that expands in the cylinder to the crankshaft through the connecting rod. Elastic bolts (008, Figure 4-19) and round nuts (009) attach the piston crown (001) to the piston rod (004).
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  • Page 178: Group 4 - Drive Supply Unit And Control Elements

    AA00-4104-00AAA-043A-A Operation Manual Supply unit drive Group 4 - Drive supply unit and control elements 4.4.1 Supply unit drive The supply unit drive is installed at the driving end of the engine on the fuel side. The crankshaft gear wheel (003, Figure 4-20) moves the intermediate wheel (001).
  • Page 179 AA00-4104-00AAA-043A-A Operation Manual Supply unit drive Fig 4-20 Supply unit drive (generic) Legend Intermediate wheel Gear wheel (servo oil pumps) Flywheel Intermediate wheel Crankshaft gear wheel Crankshaft Gear wheel (servo oil pump) - 179 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 180: Starting Air Shut-Off Valve (Example)

    AA00-4325-00AAA-043A-A Operation Manual Starting air shut-off valve 4.4.2 Starting air shut-off valve The starting air shut-off valve supplies the starting air pipe with starting air. The starting air shut- off valve has a hand-wheel with three positions: • CLOSED • AUTO •...
  • Page 181 AA00-4325-00AAA-043A-A Operation Manual Starting air shut-off valve During the start sequence the MCM-20 / IOM-20 module operates the solenoid valves (014) and (016). The control air from the control air inlet (017) opens the control valve (001) through the solenoid valve CV7014C (014) and releases the pressure in the valve space (002). The valve (007) opens and starting air from the inlet chamber (012) flows through the non-return valve (010) to the starting air outlet (011).

  • Page 182: Control Air Supply (Generic)

    AA00-4605-00AAA-043A-A Operation Manual Control air supply 4.4.3 Control air supply The control air supply supplies control air to the engine. The plant supply systems supply compressed air with the specified properties at the two engine connections that follow: • Connection 45 (control air supply inlet) for usual supply •...
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  • Page 184: Local Maneuvering Stand For Unic

    AA00-4618-00AAA-043A-A Operation Manual Local maneuvering stand for UNIC 4.4.4 Local maneuvering stand for UNIC The local maneuvering stand has the local control panel (001, Figure 4-23) and is attached to the engine at the free end. The local control panel has the components necessary for engine operation.
  • Page 185 AA00-4618-00AAA-043A-A Operation Manual Local maneuvering stand for UNIC 4.4.4.1 Local control panel NOTE: If a fault occurs in the remote control, which prevents engine control from the control room, you can operate the engine from the local control panel. The local control panel (001) has the electronic components that follow: •...

  • Page 186: Pick-Up For Speed Measurement

    AA00-4628-00AAA-043A-A Operation Manual Pick-up for speed measurement 4.4.5 Pick-up for speed measurement To measure the engine speed (rpm), proximity sensors are installed in a speed pick-up unit, attached to the support near the flywheel. For safety, there are three electrically isolated proximity sensor groups as follows: •...
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  • Page 188: Group 5 - Supply Unit, Pumps And Control Valves

    AA00-5551-00AAA-043A-A Operation Manual Servo oil pump Group 5 - Supply unit, pumps and control valves 4.5.1 Servo oil pump The servo oil pumps supply the servo oil system with oil during usual operation. The number of servo oil pumps is related to the engine. The pressure value is related to the engine load.
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  • Page 190: Supply Unit

    AA00-5552-00AAA-043A-A Operation Manual Supply unit 4.5.2 Supply unit The supply unit includes the servo oil pumps and the fuel pumps. The supply unit is installed on the column at the driving end of the engine. The gear wheels and intermediate wheels in the supply unit operate the fuel pumps and servo oil pumps, refer to section 4.4.1 Supply unit drive.
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  • Page 192: Fuel Pump

    AA00-5556-00AAA-043A-A Operation Manual Fuel pump 4.5.3 Fuel pump The fuel pumps (001, Figure 4-26) supply the fuel rail with fuel at high pressure. The number of fuel pumps is related to the engine. Fig 4-26 Fuel pump (generic) Legend Fuel pump Supply unit 4.5.3.1 Function...
  • Page 193 AA00-5556-00AAA-043A-A Operation Manual Fuel pump Leakage fuel lubricates the pump plunger (003). The leakage fuel and the engine lubricating oil from the regulating sleeve (010), flows through the drain bore, into an internal bore in the housing of the fuel pump unit. 4.5.3.3 Operation with an unserviceable fuel pump If a fuel pump is unserviceable (eg the pump plunger cannot move) or the HP fuel pipe is...

  • Page 194: Pressure Control Valve

    AA00-5562-00AAA-043A-A Operation Manual Pressure control valve 4.5.4 Pressure control valve The pressure control valve (PCV) is attached to the fuel rail (007) and has the functions that follow: • Usual operation During usual operation the engine software controls the fuel pressure. The pressure in the fuel rail is less than that necessary to open the PCV, thus the PCV is usually closed.
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  • Page 196: Flow Limiting Valve

    AA00-5565-00AAA-043A-A Operation Manual Flow limiting valve 4.5.5 Flow limiting valve For each cylinder there is one flow limiting valve installed on the fuel rail. The position of the piston (003, Figure 4-27) gives the quantity of fuel for the injection. When the injection valves open, the piston (003) moves to the right until the injection stops.
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  • Page 198: Exhaust Valve Control Unit

    AA00-5612-00AAA-043A-A Operation Manual Exhaust valve control unit 4.5.6 Exhaust valve control unit The exhaust valve control units (VCU) control the servo oil to the exhaust valve of the related cylinders. The exhaust valve control units are attached to the servo oil rail. When the solenoid valve operates, servo oil is released to the slide rod.
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  • Page 200: Fuel Pump Actuator

    AA00-5583-00AAA-043A-A Operation Manual Fuel pump actuator 4.5.7 Fuel pump actuator The fuel pump actuator moves the regulating sleeve of the fuel pump and thus controls the fuel quantity, refer to section 4.5.3 Fuel pump. Each fuel pump is connected to its related actuator (for an X92 engine two fuels pumps are connected to there related actuator).
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  • Page 202: Group 6 - Scavenge Air System

    AA00-6420-00AAA-043A-A Operation Manual Scavenge air receiver Group 6 - Scavenge air system 4.6.1 Scavenge air receiver The scavenge air receiver (005, Figure 4-28) supplies the cylinders with the applicable quantity of air. The scavenge air receiver is a welded assembly attached to the cylinder block on the exhaust side.

  • Page 203: Scavenge Air Receiver - Cross Section (Example)

    AA00-6420-00AAA-043A-A Operation Manual Scavenge air receiver Fig 4-29 Scavenge air receiver - cross section (example) Legend Air space Outlet to piston underside Longitudinal wall Flap Receiver space - 203 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 204: Turbocharger

    7.3 Start the engine - general. WinGD recommends to regularly clean the turbochargers and the silencers, refer to section Clean the turbocharger during operation. This prevents or decreases contamination of the turbochargers and thus increases the time between overhauls.
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  • Page 206 AA00-6545-00AAA-043A-A Operation Manual Auxiliary blower 4.6.3 Auxiliary blower The two auxiliary blowers supply air from the air space into the receiver space during the engine start and during operation at low load. Flaps prevent airflow back from the receiver space to the air space during usual operation of the turbochargers and during engine stop.
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  • Page 208: Switch Box (Generic)

    AA00-6547-00AAA-043A-A Operation Manual Auxiliary blower switch box 4.6.4 Auxiliary blower switch box The auxiliary blower switch box controls and gives data about the condition of the auxiliary blowers. Fig 4-32 Switch box (generic) Legend Indicator (auxiliary blower No. 2 running) Restart push button Indicator (auxiliary blower No.
  • Page 209 AA00-6547-00AAA-043A-A Operation Manual Auxiliary blower switch box Page left intentionally blank - 209 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 210 Air flow Cooling water inlet Cooling water outlet Cover WinGD recommends to regularly clean the scavenge air coolers, refer to section 8.6 Clean the scavenge air cooler during operation. This prevents or decreases contamination of the scavenge air coolers and thus increases the time between overhauls.
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  • Page 212 AA00-6708-00AAA-043A-A Operation Manual Water separator 4.6.6 Water separator The water separator removes water from the scavenge air. This prevents damage and gives better combustion in the cylinders. Water occurs when the scavenge air cooler (SAC) decreases the temperature of wet air. Water also occurs during the wash procedure of the SAC. The profiles (002, Figure 4-34) hold back the water in the air flow.
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  • Page 214: Cylinder Lubrication

    AA00-7218-00AAB-043A-A Operation Manual Cylinder lubrication Group 7 - Cylinder lubrication and balancer 4.7.1 Cylinder lubrication For more data about the cylinder oil system, refer to section 3.6 Cylinder oil system. 4.7.1.1 Cylinder lubricating pump Each cylinder has a cylinder lubricating pump. The cylinder lubricating pumps are connected to the distributor pipe (mini-rail) in the rail unit.
  • Page 215 AA00-7218-00AAB-043A-A Operation Manual Cylinder lubrication 4.7.1.2 Supply of cylinder oil Cylinder oil is injected on to the cylinder liner wall through the lubricating quills installed on the circumference of the support ring. The nozzle tip in the lubricating quill has holes in specified positions. The cylinder oil flows out of these holes at high pressure.

  • Page 216: Effect Of Second Order Moments (M2V) Of The Engine

    AA00-7752-00AAA-043A-A Operation Manual Integrated electrical balancer (iELBA) 4.7.2 Integrated electrical balancer (iELBA) The optional integrated ELectrical BAlancer (iELBA) decreases second order vertical mass moments (M2v) of the engine, refer to Figure 4-36. NOTE: For the engine itself it is not necessary to install a balancer. But a balancer decreases the exitation forces of the engine.

  • Page 217: Ielba - Function

    AA00-7752-00AAA-043A-A Operation Manual Integrated electrical balancer (iELBA) Fig 4-37 iELBA - function Legend Gear wheel Housing Counterweight Column Bearing - 217 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 218 AA00-7752-00AAA-043A-A Operation Manual Integrated electrical balancer (iELBA) 4.7.2.2 Control system Each iELBA has two control cabinets (E38 and E39). The control system monitors the speed of the electric motor and the rotating speeds and phases of the counterweights (002) and of the flywheel of the engine.

  • Page 219: Ielba - Control Cabinet

    AA00-7752-00AAA-043A-A Operation Manual Integrated electrical balancer (iELBA) 4.7.2.4 Control cabinet Figure 4-38 shows the buttons and indications on the control cabinet of the iELBA. Fig 4-38 iELBA - control cabinet - 219 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 220: Ielba - Control Cabinet

    AA00-7752-00AAA-043A-A Operation Manual Integrated electrical balancer (iELBA) Tab 4-1 iELBA - control cabinet Item Function Effect Drive Power Consumption indica- Shows the electric motor current (in Ampere) tion Manual Start button Starts the iELBA (in manual mode) Manual Stop button Stops the iELBA (in manual mode) Power 24V indicator light Shows if electric power is on...

  • Page 221: Ielba - Error Indication

    AA00-7752-00AAA-043A-A Operation Manual Integrated electrical balancer (iELBA) Table 4-2 - iELBA - error indication shows the possible iELBA error indications related to the number of flashes of the indicator light. NOTE: The error indications are active in automatic mode and in manual mode. Tab 4-2 iELBA - error indication Number of...
  • Page 222 AA00-8135-00AAA-043A-A Operation Manual Exhaust waste gate Group 8 - Piping 4.8.1 Exhaust waste gate The optional exhaust waste gate is a by-pass pipe to the turbine (006, Figure 4-39) of the turbochargers. The valve (007) in this pipe controls the flow of exhaust gas through the turbines (006).
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  • Page 224 AA00-9223-00AAA-043A-A Operation Manual Crank angle sensor unit Group 9 - Monitoring system 4.9.1 Crank angle sensor unit The crank angle sensor unit is installed on the supply unit drive at the driving end. There are two crank angle systems that monitor the teeth on the intermediate wheel. The two sets of proximity sensors operate independently to sense the teeth on the intermediate wheel (002).

  • Page 225: Crank Angle Sensor Unit On Flywheel (Example)

    AA00-9223-00AAA-043A-A Operation Manual Crank angle sensor unit Two more proximity sensors (002, Figure 4-40) are used to find the crank angle marks (004) for TDC and BDC on the flywheel (003). All proximity sensors are connected as follows: • First sensor pair to MCM-20 and CCM-20#1 •...
  • Page 226 AA00-9313-00AAA-043A-A Operation Manual Water in oil monitor 4.9.2 Water in oil monitor The optional water in oil monitor continuously monitors the concentration of water in the oil supply pipe. The water in oil monitor continuously sends a signal to the alarm and monitoring system (AMS).
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  • Page 228 AA00-9314-00AAA-043A-A Operation Manual Oil mist detector 4.9.3 Oil mist detector The oil mist detection system continuously monitors the concentration of oil mist in the crankcase, in the supply unit drive and in the supply unit. If there is a high oil mist concentration, the oil mist detector activates an alarm.

  • Page 229: Oil Mist Detector - Schematic Diagram (Example)

    AA00-9314-00AAA-043A-A Operation Manual Oil mist detector Fig 4-43 Oil mist detector - schematic diagram (example) Legend Control panel Control unit E15.1 Power supply Supply unit Data cable Crankcase and gear box To alarm system Sensor To safety system Data communication is between the control unit (006, Figure 4-43) and the control panel (001).
  • Page 230 AA00-9606-00AAA-042A-A Operation Manual Integrated sensor and pressure relief valve 4.9.4 Integrated sensor and pressure relief valve An integrated sensor and pressure relief valve are installed on each cylinder cover. The integrated sensor measures the pressure inside the cylinder. (online sensor) The pressure relief valve with integrated online sensor is used to avoid the gas pockets in the cylinders.

  • Page 231: Control System Of The Engine

    Operation Manual 5 Control system of the engine Engine control system UNIC..........232 Intelligent combustion control.

  • Page 232: Engine Control System Unic

    The engine control system (ECS) is an embedded system that has a modular design. Some parts and functions in the ECS system configuration are optional and are related to the application. The name of the WinGD engine control system is UNIfied Controls Flex (UNIC-flex). It has the items that follow: •...

  • Page 233: Ecs Modules

    AA00-0000-00AAA-043K-A Operation Manual Engine control system UNIC Fig 5-1 ECS modules 00214 Legend Input output module (IOM-10) Cylinder control module (CCM-20) Main control module (MCM-11) Local display unit (LDU-20) 5.1.2 Functions of the engine control system The main functions of the engine control system are as follows: •...
  • Page 234 AA00-0000-00AAA-043K-A Operation Manual Engine control system UNIC 5.1.3 External control systems The Diesel Engine CoNtrol and OptImizing Specification (DENIS) and the engine control system (ECS) are designed so that different remote controls can be used. All nodes are fully specified. The terminal boxes are installed on the engine, to which the cable ends from the control room or from the bridge can be connected.
  • Page 235 AA00-0000-00AAA-043K-A Operation Manual Engine control system UNIC 5.1.3.2 Alarm and monitoring system The alarm and monitoring system (AMS) is an external system and monitors the engine. The AMS gives the operator alarms and status data of the engine to make sure of safe and satisfactory engine operation.

  • Page 236: Signal Flow Diagram

    AA00-0000-00AAA-043K-A Operation Manual Engine control system UNIC Fig 5-2 Signal flow diagram Signals for Alarm / Indication Signals for Alarm Signals for Alarm and Slowdown Indications UNIC Alarm Signals Feedback Signals from UNIC Command Orders from RCS Ethernet to ECR Manual Control Signals for Safety Signals for Control Gas SHD and Venting GVU / iGPR*...
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  • Page 238: Intelligent Combustion Control

    AA00-9308-00AAA-043A-A Operation Manual Intelligent combustion control Intelligent combustion control The intelligent combustion control (ICC) permanently monitors and automatically controls the combustion process. The ICC is part of the engine control system (ECS). All ICC modifications of the engine control parameters obey the IMO regulations and are related to the IMO certificate of the vessel. The ICC calculates the best engine control parameters for operation, which balances the compression and firing pressures in the engine (for example injection time offsets and exhaust valve closing time for each cylinder).

  • Page 239: Icc - Pressure Diagram

    AA00-9308-00AAA-043A-A Operation Manual Intelligent combustion control 5.2.1 Pressure calculation In the ICC system, the compression pressure of each cycle is calculated with the polynomial formula and the data of the piston position. The ICC uses the values that follow for calculation, refer to Figure 5-3:...

  • Page 240: Icc - Control Schematic

    AA00-9308-00AAA-043A-A Operation Manual Intelligent combustion control 5.2.2 ICC control A pressure transmitter is installed on each cylinder cover. The cylinder pressure data of each cylinder is taken as an analogue input signal from the pressure transmitter into the ECS. The ECS filters the signals from the sensors and then transmits these signals to a controller. The measured value is adjusted to the correct setpoint value and is related to the engine load.
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  • Page 242: Local Display Unit (Ldu-20) Pages For Unic

    AA00-9606-01AAA-043A-A Operation Manual LDU-20 pages - general Local display unit (LDU-20) pages for UNIC 5.3.1 LDU-20 pages - general In the chapters that follow you can find a description of the LDU-20 pages that follow: • 5.3.2 LDU-20 page - MAIN •...
  • Page 243 AA00-9606-01AAA-043A-A Operation Manual LDU-20 pages - general Page left intentionally blank - 243 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 244 AA00-9606-02AAA-043A-A Operation Manual LDU-20 page - MAIN 5.3.2 LDU-20 page - MAIN Fig 5-5 MAIN - 244 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 245 AA00-9606-02AAA-043A-A Operation Manual LDU-20 page - MAIN Tab 5-1 MAIN Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL. TR. button Sends a signal for a control transfer to this LDU-20 OVERRIDE button Cancels a shutdown from the safety system...
  • Page 246 AA00-9606-02AAA-043A-A Operation Manual LDU-20 page - MAIN Item Function Effect Manual fuel command setpoint Manually adjust the fuel command setpoint between 0% and 150% Fuel Command button Changes to manual fuel command mode - 246 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
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  • Page 248: Control Locations

    AA00-9606-03AAA-043B-A Operation Manual LDU-20 page - CONTROL LOCATIONS 5.3.3 LDU-20 page - CONTROL LOCATIONS Fig 5-6 CONTROL LOCATIONS 00153 - 248 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 249: Control Locations

    AA00-9606-03AAA-043B-A Operation Manual LDU-20 page - CONTROL LOCATIONS Tab 5-2 CONTROL LOCATIONS Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 250: Ca Sensor Status

    AA00-9606-05AAA-043B-A Operation Manual LDU-20 page - CA SENSOR STATUS 5.3.4 LDU-20 page - CA SENSOR STATUS Fig 5-7 CA SENSOR STATUS - 250 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 251 AA00-9606-05AAA-043B-A Operation Manual LDU-20 page - CA SENSOR STATUS Tab 5-3 CA SENSOR STATUS Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 252: Cylinder Balancing Diesel

    AA00-9606-06AAA-043B-A Operation Manual LDU-20 page - CYLINDER BALANCING DIESEL 5.3.5 LDU-20 page - CYLINDER BALANCING DIESEL Fig 5-8 CYLINDER BALANCING DIESEL - 252 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 253: Cylinder Balancing Diesel

    AA00-9606-06AAA-043B-A Operation Manual LDU-20 page - CYLINDER BALANCING DIESEL Tab 5-4 CYLINDER BALANCING DIESEL Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 254: Page - Cylinder Lubrication

    AA00-9606-08AAA-043B-A Operation Manual LDU-20 page - CYLINDER LUBRICATION 5.3.6 LDU-20 page - CYLINDER LUBRICATION Fig 5-9 CYLINDER LUBRICATION NOTE: Some indications on this LDU-20 page are only applicable for a DF engine. - 254 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 255 AA00-9606-08AAA-043B-A Operation Manual LDU-20 page - CYLINDER LUBRICATION Tab 5-5 CYLINDER LUBRICATION Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 256: Page - Icat

    AA00-9606-09AAA-043B-A Operation Manual LDU-20 page - iCAT 5.3.7 LDU-20 page - iCAT Fig 5-10 iCAT (integrated Cylinder lubricant Auto Transfer) - 256 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 257 AA00-9606-09AAA-043B-A Operation Manual LDU-20 page - iCAT Tab 5-6 iCAT (integrated Cylinder lubricant Auto Transfer) Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
  • Page 258 AA00-9606-09AAA-043B-A Operation Manual LDU-20 page - iCAT Item Function Effect Index button Opens the INDEX page Print button Makes a screenshot of the current screen, refer to section 5.3.21 LDU-20 page - SCREENSHOT Transfer Mode status Shows the transfer mode status: •...
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  • Page 260: Dynamic Combustion Control (Dcc)

    AA00-9606-10AAA-043B-A Operation Manual LDU-20 page - DYNAMIC COMBUSTION CONTROL (DCC) 5.3.8 LDU-20 page - DYNAMIC COMBUSTION CONTROL (DCC) Fig 5-11 DYNAMIC COMBUSTION CONTROL (DCC) - 260 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 261 AA00-9606-10AAA-043B-A Operation Manual LDU-20 page - DYNAMIC COMBUSTION CONTROL (DCC) Tab 5-7 DYNAMIC COMBUSTION CONTROL (DCC) Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 262: Exhaust Ventilation

    AA00-9606-11AAA-043B-A Operation Manual LDU-20 page - EXHAUST VENTILATION 5.3.9 LDU-20 page - EXHAUST VENTILATION Fig 5-12 EXHAUST VENTILATION - 262 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 263: Exhaust Ventilation

    AA00-9606-11AAA-043B-A Operation Manual LDU-20 page - EXHAUST VENTILATION NOTE: For a description of the exhaust ventilation refer to section [section not applicable for this engine]. Tab 5-8 EXHAUST VENTILATION Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button...

  • Page 264: Exhaust Valves

    AA00-9606-12AAA-043B-A Operation Manual LDU-20 page - EXHAUST VALVES 5.3.10 LDU-20 page - EXHAUST VALVES Fig 5-13 EXHAUST VALVES - 264 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 265 AA00-9606-12AAA-043B-A Operation Manual LDU-20 page - EXHAUST VALVES Tab 5-9 EXHAUST VALVES Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 266: Failure List

    AA00-9606-13AAA-043B-A Operation Manual LDU-20 page - FAILURE LIST 5.3.11 LDU-20 page - FAILURE LIST Fig 5-14 FAILURE LIST - 266 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 267 AA00-9606-13AAA-043B-A Operation Manual LDU-20 page - FAILURE LIST Tab 5-10 FAILURE LIST Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 268: Failure Simulation

    AA00-9606-14AAA-043B-A Operation Manual LDU-20 page - FAILURE SIMULATION 5.3.12 LDU-20 page - FAILURE SIMULATION Fig 5-15 FAILURE SIMULATION - 268 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 269: Failure Simulation

    AA00-9606-14AAA-043B-A Operation Manual LDU-20 page - FAILURE SIMULATION Tab 5-11 FAILURE SIMULATION Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 270: Fuel System

    AA00-9606-16AAA-043B-A Operation Manual LDU-20 page - FUEL SYSTEM 5.3.13 LDU-20 page - FUEL SYSTEM Fig 5-16 FUEL SYSTEM NOTE: Some indications on this LDU-20 page are only applicable for a DF engine. - 270 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 271 AA00-9606-16AAA-043B-A Operation Manual LDU-20 page - FUEL SYSTEM Tab 5-12 FUEL SYSTEM Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 272: Knock Control

    AA00-9606-21AAA-043B-A Operation Manual LDU-20 page - KNOCK CONTROL 5.3.14 LDU-20 page - KNOCK CONTROL Fig 5-17 KNOCK CONTROL - 272 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 273: Knock Control

    AA00-9606-21AAA-043B-A Operation Manual LDU-20 page - KNOCK CONTROL Tab 5-13 KNOCK CONTROL Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 274: Log Messages

    AA00-9606-22AAA-043B-A Operation Manual LDU-20 page - LOG MESSAGES 5.3.15 LDU-20 page - LOG MESSAGES Fig 5-18 LOG MESSAGES 00164 - 274 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 275 AA00-9606-22AAA-043B-A Operation Manual LDU-20 page - LOG MESSAGES Tab 5-14 LOG MESSAGES Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 276: Main Fuel Injection

    AA00-9606-23AAA-043B-A Operation Manual LDU-20 page - MAIN FUEL INJECTION 5.3.16 LDU-20 page - MAIN FUEL INJECTION Fig 5-19 MAIN FUEL INJECTION - 276 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 277 AA00-9606-23AAA-043B-A Operation Manual LDU-20 page - MAIN FUEL INJECTION Tab 5-15 MAIN FUEL INJECTION Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 278: Performance Data Diesel

    AA00-9606-25AAA-043B-A Operation Manual LDU-20 page - PERFORMANCE DATA DIESEL 5.3.17 LDU-20 page - PERFORMANCE DATA DIESEL Fig 5-20 PERFORMANCE DATA DIESEL - 278 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 279 AA00-9606-25AAA-043B-A Operation Manual LDU-20 page - PERFORMANCE DATA DIESEL Tab 5-16 PERFORMANCE DATA DIESEL Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 280: Pilot Fuel Injection

    AA00-9606-27AAA-043B-A Operation Manual LDU-20 page - PILOT FUEL INJECTION 5.3.18 LDU-20 page - PILOT FUEL INJECTION Fig 5-21 PILOT FUEL INJECTION - 280 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 281 AA00-9606-27AAA-043B-A Operation Manual LDU-20 page - PILOT FUEL INJECTION Tab 5-17 PILOT FUEL INJECTION Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 282: Pilot Fuel Pressure

    AA00-9606-28AAA-043B-A Operation Manual LDU-20 page - PILOT FUEL PRESSURE 5.3.19 LDU-20 page - PILOT FUEL PRESSURE Fig 5-22 PILOT FUEL PRESSURE - 282 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 283 AA00-9606-28AAA-043B-A Operation Manual LDU-20 page - PILOT FUEL PRESSURE Tab 5-18 PILOT FUEL PRESSURE Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 284: Scavenge Air - Ewg (Optional)

    AA00-9606-29AAA-043B-A Operation Manual LDU-20 page - SCAVENGE AIR - EWG (optional) 5.3.20 LDU-20 page - SCAVENGE AIR - EWG (optional) Fig 5-23 SCAVENGE AIR - EWG (optional) - 284 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 285 AA00-9606-29AAA-043B-A Operation Manual LDU-20 page - SCAVENGE AIR - EWG (optional) This LDU-20 page is only applicable, if the engine has a controllable exhaust waste gate. Tab 5-19 SCAVENGE AIR - EWG (optional) Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button...

  • Page 286: Page - Screenshot

    AA00-9606-30AAA-043B-A Operation Manual LDU-20 page - SCREENSHOT 5.3.21 LDU-20 page - SCREENSHOT This function saves a screenshot of the page to a USB drive (if connected). The saved screenshot is a 640 x 480 pixel image in the xx.png format. When you save a screenshot, the pop-up text Screenshot saved shows on the bottom right- hand corner of the display.
  • Page 287 AA00-9606-30AAA-043B-A Operation Manual LDU-20 page - SCREENSHOT Page left intentionally blank - 287 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 288: Software Info

    AA00-9606-31AAA-043B-A Operation Manual LDU-20 page - SOFTWARE INFO 5.3.22 LDU-20 page - SOFTWARE INFO Fig 5-24 SOFTWARE INFO - 288 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 289 AA00-9606-31AAA-043B-A Operation Manual LDU-20 page - SOFTWARE INFO Tab 5-20 SOFTWARE INFO Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 290: Imo Crc Info

    AA00-9606-32AAA-043B-A Operation Manual LDU-20 page - IMO CRC INFO 5.3.23 LDU-20 page - IMO CRC INFO Fig 5-25 IMO CRC INFO - 290 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 291 AA00-9606-32AAA-043B-A Operation Manual LDU-20 page - IMO CRC INFO Tab 5-21 IMO CRC INFO Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 292: Software Tools

    AA00-9606-33AAA-043B-A Operation Manual LDU-20 page - SOFTWARE TOOLS 5.3.24 LDU-20 page - SOFTWARE TOOLS Fig 5-26 SOFTWARE TOOLS 00167 - 292 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 293 AA00-9606-33AAA-043B-A Operation Manual LDU-20 page - SOFTWARE TOOLS Tab 5-22 SOFTWARE TOOLS Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 294: System Status

    AA00-9606-34AAA-043B-A Operation Manual LDU-20 page - SYSTEM STATUS 5.3.25 LDU-20 page - SYSTEM STATUS Fig 5-27 SYSTEM STATUS 00166 - 294 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 295 AA00-9606-34AAA-043B-A Operation Manual LDU-20 page - SYSTEM STATUS Tab 5-23 SYSTEM STATUS Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 296: System Settings

    AA00-9606-35AAA-043B-A Operation Manual LDU-20 page - SYSTEM SETTINGS 5.3.26 LDU-20 page - SYSTEM SETTINGS Fig 5-28 SYSTEM SETTINGS 00169 - 296 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 297 AA00-9606-35AAA-043B-A Operation Manual LDU-20 page - SYSTEM SETTINGS Tab 5-24 SYSTEM SETTINGS Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 298: Page - Temperatures

    AA00-9606-36AAA-043B-A Operation Manual LDU-20 page - TEMPERATURES 5.3.27 LDU-20 page - TEMPERATURES Fig 5-29 TEMPERATURES - 298 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 299 AA00-9606-36AAA-043B-A Operation Manual LDU-20 page - TEMPERATURES Tab 5-25 TEMPERATURES Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL. TR. button Sends a signal for a control transfer to this LDU-20 PRINT button Makes a screenshot of the current screen, refer to...

  • Page 300: User Parameters

    AA00-9606-37AAA-043B-A Operation Manual LDU-20 page - USER PARAMETERS 5.3.28 LDU-20 page - USER PARAMETERS Fig 5-30 USER PARAMETERS 00159 - 300 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 301 AA00-9606-37AAA-043B-A Operation Manual LDU-20 page - USER PARAMETERS Tab 5-26 USER PARAMETERS Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.

  • Page 302: Log Entry Data

    AA00-9606-39AAA-043B-A Operation Manual LDU-20 page - LOG ENTRY DATA 5.3.29 LDU-20 page - LOG ENTRY DATA Fig 5-31 LOG ENTRY DATA 00165 - 302 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 303 AA00-9606-39AAA-043B-A Operation Manual LDU-20 page - LOG ENTRY DATA NOTE: Some data on this screen are only applicable to WinGD SW developers, eg the ID and status flag numbers. Tab 5-27 LOG ENTRY DATA Item Function Effect START AST button...

  • Page 304: Page - Date

    AA00-9606-40AAA-043B-A Operation Manual LDU-20 page - DATE 5.3.30 LDU-20 page - DATE Fig 5-32 DATE - 304 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 305 AA00-9606-40AAA-043B-A Operation Manual LDU-20 page - DATE Tab 5-28 DATE Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL. TR. button Sends a signal for a control transfer to this LDU-20 Save config button Saves the configuration settings...

  • Page 306: Page - Ethernet

    AA00-9606-41AAA-043B-A Operation Manual LDU-20 page - ETHERNET 5.3.31 LDU-20 page - ETHERNET Fig 5-33 ETHERNET - 306 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 307 AA00-9606-41AAA-043B-A Operation Manual LDU-20 page - ETHERNET Tab 5-29 ETHERNET Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL. TR. button Sends a signal for a control transfer to this LDU-20 Save config button Saves the configuration settings...

  • Page 308: Overview

    AA00-0000-00AAA-043H-A Operation Manual Local display unit (LDU-20) - general Control pages for other systems 5.4.1 Local display unit (LDU-20) - general 5.4.1.1 Local display unit (LDU-20) The LDU-20 (Figure 5-34) is a multi-purpose module that has an LCD color display (009), ten multi-function buttons (004 to 008) and a rotary button (003).

  • Page 309: Color Display - General Items

    AA00-0000-00AAA-043H-A Operation Manual Local display unit (LDU-20) - general 5.4.1.2 Color display The color display (009) of the LDU-20 shows different pages for each application. After boot-up, or when you push the HOME button, the MAIN page is shown. Some elements are shown on all pages as follows: •...

  • Page 310: Operate The Local Display Unit (Ldu-20)

    AA00-0000-00AAA-131I-A Operation Manual Operate the local display unit (LDU-20) 5.4.2 Operate the local display unit (LDU-20) Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...

  • Page 311: Navigation Menu

    AA00-0000-00AAA-131I-A Operation Manual Operate the local display unit (LDU-20) PROCEDURE Fig 5-36 LDU-20 - navigation menu 00210 To change between LDU-20 pages, do the steps that follow: Push and hold the rotary button for three seconds to show the page navigation menu (001, Figure 5-36).
  • Page 312 AA00-0000-00AAA-131I-A Operation Manual Operate the local display unit (LDU-20) To operate the engine from the MAIN page, do the steps that follow: NOTE: The changes have an immediate effect on the engine. Make sure that the LDU-20 is the active control location. If necessary, select the CTRL.TR button to transfer control.
  • Page 313 Push the rotary button to take a screenshot of the page. NOTE: The screenshot will be automatically saved to the USB drive. If necessary, send the saved xx.png file to WinGD. To download backup files from the SYSTEM STATUS page, do the steps that follow: NOTE: The dialog box that is shown gives an option to download, or not to download the backup files to the selected modules.
  • Page 314 AA00-0000-00AAA-131I-A Operation Manual Operate the local display unit (LDU-20) 10.1 Use the rotary button (turn and then push) to select the DOWNLOAD button. 10.2 Select Yes to start the download backup files procedure. NOTE: Select NO if you want to cancel the procedure. - 314 - Issue 001 2021-01 Winterthur Gas &...
  • Page 315 NOTE: You use the partial upgrade wizard to adjust software parameters, which the user does not usually have access. A file from WinGD stored on a USB drive is necessary. NOTE: Connect the USB drive to the USB port on the back of the LDU-20.
  • Page 316 AA00-0000-00AAA-131I-A Operation Manual Operate the local display unit (LDU-20) Page left intentionally blank - 316 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 317 Operation Manual 6 Installation of the engine Installation............. . - 317 - Issue 001 2021-01 Winterthur Gas &...
  • Page 318 • Engine stays • Extinguishing system • Auxiliary systems. NOTE: The latest version of the Marine Installation Manual and the installation drawings are available on the WinGD website. https://www.wingd.com/ - 318 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 319: Operation Of The Engine

    Operation Manual 7 Operation of the engine Prepare the engine before start - general........320 Prepare the engine before start.
  • Page 320 AA00-0000-00AAA-120A-A Operation Manual Prepare the engine before start - general Prepare the engine before start - general If you have done maintenance work on the engine, make sure that you have done the related function tests and the engine is ready for operation. Do checks on the systems that follow to make sure that the engine is ready for engine start.
  • Page 321 AA00-0000-00AAA-120A-A Operation Manual Prepare the engine before start - general • Control air system Make sure that the quality of the control air obeys the related specifications in section 11.2 Compressed air. Make sure that control air is available at the engine connection 49 (control air supply inlet).
  • Page 322 AA00-0000-00AAA-121A-A Operation Manual Prepare the engine before start Prepare the engine before start Periodicity Description Engine start Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description Specialization...
  • Page 323 AA00-0000-00AAA-121A-A Operation Manual Prepare the engine before start PROCEDURE Make sure that there is no alarm indication. Prepare the control system for operation. Set to ON the engine control system (ECS) and the remote control system (RCS). Set to ON all circuit breakers in the power supply box E85. Set to ON the control box for the cylinder oil filter (refer to the documentation of the manufacturer).

  • Page 324: Cooling Water System With Bypass Cooling

    AA00-0000-00AAA-121A-A Operation Manual Prepare the engine before start Prepare the cooling water system for operation. For an engine with a bypass cooling water system (refer to Figure 7-1), and when the liner wall temperature is between 60°C and 90°C (for example when the engine is pre-heated or after engine full stop for a sufficient period), release the unwanted air with a high flow rate as follows: Fig 7-1...

  • Page 325: Cooling Water System Without Bypass Cooling

    AA00-0000-00AAA-121A-A Operation Manual Prepare the engine before start For an engine without a bypass cooling water system (refer to Figure 7-2), and when the liner wall temperature is between 60°C and 90°C (for example when the engine is pre-heated or after engine full stop for a sufficient period), release the unwanted air with a high flow rate as follows: Fig 7-2 Cooling water system without bypass cooling...

  • Page 326: Cooling Water System With Circulation

    AA00-0000-00AAA-121A-A Operation Manual Prepare the engine before start For an engine with an internal circulation cooling water system (with circulation pump and temperature control valve, refer to Figure 7-3), and when the liner wall temperature is between 60°C and 90°C (for example when the engine is pre- heated or after engine full stop for a sufficient period), release the unwanted air with a high flow rate as follows: Fig 7-3...
  • Page 327 AA00-0000-00AAA-121A-A Operation Manual Prepare the engine before start Prepare the air systems for operation. Set all valves to their correct positions for operation. Drain the air system at the related drain valves. 4.2.1 Open the first drain valve. 4.2.2 After no more water flows out from the valve, close the drain valve. 4.2.3 Step 4.2.1 Step 4.2.2...
  • Page 328 AA00-0000-00AAA-121A-A Operation Manual Prepare the engine before start For a DF engine, prepare the gas system for operation. Do a visual check of the gas pipes for damage. If damage is found, replace the defective gas pipes immediately. Do the gas related checks. If alarms or failure messages occur, repair the related item.
  • Page 329 AA00-0000-00AAA-121A-A Operation Manual Prepare the engine before start Page left intentionally blank - 329 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 330 AA00-0000-00AAA-130A-A Operation Manual Start the engine - general Start the engine - general 7.3.1 Usual start conditions The engine must be prepared for operation. All the auxiliary systems must be in correct operation related to section 7.2 Prepare the engine before start.
  • Page 331 AA00-0000-00AAA-130A-A Operation Manual Start the engine - general • For an engine with three turbochargers and one or two turbochargers are defective: Make sure that the exhaust gas temperature at the serviceable turbochargers inlet is less than the maximum permitted temperature. If one turbocharger is defective, the maximum power output of the engine is approximately 66% related to the power of the serviceable turbochargers.
  • Page 332 AA00-0000-00AAA-131A-A Operation Manual Start the engine Start the engine Periodicity Description Engine start Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description Specialization Engine crew Intermediate Support equipment...
  • Page 333 AA00-0000-00AAA-131A-A Operation Manual Start the engine PROCEDURE If there is a clutch coupling between engine and propeller, do the steps that follow: Engage the clutch coupling. Keep the clutch coupling engaged during operation to prevent damage to the engine. Select the applicable control panel. Start the auxiliary blowers.
  • Page 334 AA00-0000-00AAA-130B-A Operation Manual Do checks during operation - general Do checks during operation - general During operation, do regular checks of the operating values, refer to section 7.6 Do checks during operation. This prevents damage to the engine if malfunctions occur. Compare the values with those given in the acceptance records.
  • Page 335 AA00-0000-00AAA-130B-A Operation Manual Do checks during operation - general Page left intentionally blank - 335 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 336 AA00-0000-00AAA-131B-A Operation Manual Do checks during operation Do checks during operation Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description Specialization Engine crew Intermediate...
  • Page 337 AA00-0000-00AAA-131B-A Operation Manual Do checks during operation PROCEDURE Make sure that the engine control system indicates no alarm signals. If there are alarm signals, find the cause and repair the fault. Listen to the engine for unusual noise. If you hear unusual noise, find the cause and repair the fault.
  • Page 338 AA00-0000-00AAA-131B-A Operation Manual Do checks during operation For a DF engine, do also the checks that follow: 13.1 Do regular checks (leak checks) of the gas piping system, refer to the related data or documentation. 13.2 Do daily a check of the cylinder compression pressures on the related control panel.
  • Page 339 AA00-0000-00AAA-131B-A Operation Manual Do checks during operation Page left intentionally blank - 339 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 340 AA00-0000-00AAA-340A-A Operation Manual Do regular safety checks Do regular safety checks Periodicity Description Months Unscheduled After maintenance work Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 4.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 341 AA00-0000-00AAA-340A-A Operation Manual Do regular safety checks PROCEDURE Make sure that the remote control system (RCS), the engine safety system (ESS), and the alarm and monitoring system (AMS) are set to ON. Do a check of the EMERGENCY STOP buttons: On the control panel in the engine control room (ECR), push the EMERGENCY STOP button.
  • Page 342 AA00-0000-00AAA-340A-A Operation Manual Do regular safety checks Set to ON the electrical power supply for each auxiliary blower. Get control at the local control panel. Start the auxiliary blowers. 6.6.1 Make sure that the auxiliary blower 1 starts immediately. 6.6.2 Make sure that the auxiliary blower 2 starts after an interval of between 3 to 6 seconds.
  • Page 343 AA00-0000-00AAA-340A-A Operation Manual Do regular safety checks Step 8.1 Step 8.8 again from the locations that follow: • Control panel in the engine control room (ECR) • Remote control. 8.10 Make sure that the supply of starting air to the starting air supply pipe is possible: 8.10.1 Close the two drain valves in the starting air supply pipe.
  • Page 344 AA00-0000-00AAA-130C-A Operation Manual Maneuver the ship - general Maneuver the ship - general Maneuvering is the operation between leaving a port and approaching to port. Maneuvering also includes all changes during usual operation, for example changing of direction. The conditions as follows affect the speed of the ship: •...
  • Page 345 AA00-0000-00AAA-130C-A Operation Manual Maneuver the ship - general 7.8.2 Maneuvering at overload The engine should only be operated at overload (110% of CMCR power) during sea trials and when there is an authorized representative of the engine builder on board the ship. The limit for operation of the engine at overload is a maximum of one hour each day (refer also to section 2.3 The relation between engine and propeller).
  • Page 346 AA00-0000-00AAA-131C-A Operation Manual Maneuver the ship Maneuver the ship Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description Specialization Engine crew Intermediate Support equipment Description...
  • Page 347 AA00-0000-00AAA-131C-A Operation Manual Maneuver the ship PROCEDURE Select the applicable control console. To change the speed, do the steps that follow: Use the rotary button to select the fuel command button. Turn the rotary button to set the related fuel injection quantity. NOTE: Refer to the time limits given in section 7.8 Maneuver the ship -...
  • Page 348 In this situation a change-over is not possible. 7.10.1 Automatic fuel change-over WinGD recommends the installation and use of an automatic fuel change-over system to prevent problems during the change-over procedure. •...
  • Page 349 BN. For more data refer to the related procedures. 7.10.4.1 Engine with iCAT If the engine has an iCAT system (integrated Cylinder lubricant Auto Transfer system), WinGD recommends as follows, when you change-over the fuel: • If the iCAT system is in auto mode, the iCAT system automatically changes-over the cylinder oil at the correct time.

  • Page 350: Cylinder Lubricant Quantity

    AA00-0000-00AAA-130D-A Operation Manual Change-over the diesel fuel - general Fig 7-4 Cylinder lubricant quantity Cylinder lubricant quantity in piping and measuring tank: ∗ ∗ [ ] = [ ] = [ ] = Volume piping: ∑ = ∑ ∗ Mass: [ ] = [ ] = [ ] =...
  • Page 351 AA00-0000-00AAA-130D-A Operation Manual Change-over the diesel fuel - general Page left intentionally blank - 351 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 352 • None PRELIMINARY OPERATIONS • WinGD recommends to always do this automatic change-over procedure when possible. There is no load limit of the engine to do an automatic fuel change-over. - 352 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 353 AA00-0000-00AAA-131E-A Operation Manual Change-over the diesel fuel automatically PROCEDURE Start the automatic change-over procedure, refer to the instructions of the manufacturer. CLOSE UP • None - 353 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 354 • None PRELIMINARY OPERATIONS • WinGD recommends to do a manual change-over only, if an automatic change-over system is not installed or if the automatic change-over system is unserviceable. - 354 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 355 AA00-0000-00AAA-131D-A Operation Manual Change-over from HFO to MDO manually PROCEDURE Make a full time schedule for the change-over to obey the ECA rules. If you operate the engine with MDO for a long period, you must change the cylinder oil to the applicable BN at the related time, refer to section 7.10 Change-over the diesel fuel -...
  • Page 356 • None PRELIMINARY OPERATIONS • WinGD recommends to do a manual change-over only, if an automatic change-over system is not installed or if the automatic change-over system is unserviceable. - 356 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 357 AA00-0000-00AAA-131H-A Operation Manual Change-over from MDO to HFO manually PROCEDURE Make a full time schedule for the change-over to obey the ECA rules. Make sure that you have changed the cylinder oil to the applicable BN, refer to section 7.10 Change-over the diesel fuel - general.
  • Page 358 At the local control panel of the engine. Related to the situation and to the planned tasks after engine shutdown, WinGD recommends to operate the engine with marine diesel oil (MDO) for some time before you stop the engine, refer to section 7.12 Change-over from HFO to MDO...
  • Page 359 AA00-0000-00AAA-130G-A Operation Manual Stop the engine - general Page left intentionally blank - 359 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 360 AA00-0000-00AAA-131G-A Operation Manual Stop the engine 7.15 Stop the engine Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description Specialization Engine crew Intermediate Support equipment...
  • Page 361 AA00-0000-00AAA-131G-A Operation Manual Stop the engine PROCEDURE Select the applicable control panel. Decrease the engine load to the minimum. On the control panel push the STOP button. NOTE: The ECS shuts down the engine in a controlled manner. For a DF engine, start the exhaust ventilation sequence, if there is a ventilation request. CLOSE UP •...
  • Page 362 AA00-0000-00AAA-140A-A Operation Manual Emergency stop the engine - general 7.16 Emergency stop the engine - general To stop the engine in an emergency, do the procedure given in section 7.17 Emergency stop the engine. - 362 - Issue 001 2021-01 Winterthur Gas &...
  • Page 363 AA00-0000-00AAA-140A-A Operation Manual Emergency stop the engine - general Page left intentionally blank - 363 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 364 AA00-0000-00AAA-141A-A Operation Manual Emergency stop the engine 7.17 Emergency stop the engine Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.1 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description Specialization Engine crew...
  • Page 365 AA00-0000-00AAA-141A-A Operation Manual Emergency stop the engine PROCEDURE In the control room (control console), or on the local control panel, push the EMERGENCY STOP button. NOTE: The ECS stops the engine immediately. For a DF engine, start the exhaust ventilation sequence, if there is a ventilation request. To make the engine ready for restart after an emergency stop, you must reset the EMERGENCY STOP button.
  • Page 366 AA00-0000-00AAA-150A-A Operation Manual Prepare the engine after stop - general 7.18 Prepare the engine after stop - general After a decrease of the engine speed to less than 8% the ECS automatically starts the post- lubrication of the cylinders. NOTE: The water and oil pumps must operate for a minimum of 20 minutes after the engine has stopped.
  • Page 367 AA00-0000-00AAA-150A-A Operation Manual Prepare the engine after stop - general Page left intentionally blank - 367 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 368 AA00-0000-00AAA-151A-A Operation Manual Prepare the engine for a short service break 7.19 Prepare the engine for a short service break Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 369 AA00-0000-00AAA-151A-A Operation Manual Prepare the engine for a short service break PROCEDURE Make sure that the auxiliary systems continue to operate. If possible, keep the cooling water warm to prevent too much temperature decrease of the engine. Open the indicator valves in the cylinder covers. Engage the turning gear.
  • Page 370 AA00-0000-00AAA-151B-A Operation Manual Prepare the engine for standstill or for maintenance 7.20 Prepare the engine for standstill or for maintenance Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 371 AA00-0000-00AAA-151B-A Operation Manual Prepare the engine for standstill or for maintenance PROCEDURE Open the indicator valves in the cylinder covers. Engage the turning gear. Stop the fuel supply to the engine as follows: Stop the fuel supply system from the plant. Close the shut-off valve at engine connection 49 (fuel inlet).
  • Page 372 AA00-0000-00AAA-151B-A Operation Manual Prepare the engine for standstill or for maintenance For a DF engine, stop the gas system. If you have to do maintenance downstream of the block valve (CV7285), do as follows: 8.1.1 Make sure that the valve positions are in degassing state. 8.1.2 On the iGPR cabinet switch the button S8 to maintenance to activate the maintenance mode.
  • Page 373 12.2.2 Find the cause and repair the fault. 12.3 If necessary, apply anti-corrosion oil to give protection. If the engine must have preservation for a long period, speak to or send a message to WinGD for the applicable preservation procedures. CLOSE UP • None...
  • Page 374 AA00-9270-00AAA-100B-A Operation Manual LP-SCR system: Change Tier mode 7.21 LP-SCR system: Change Tier mode The low pressure selective catalytic reduction system (LP-SCR) has 3 different operation modes. • Tier II mode • Prepare Tier III mode • Tier III mode Before changing modes, make sure these preconditions are fulfilled: •...

  • Page 375: Select: Prepare Tier Iii

    AA00-9270-00AAA-100B-A Operation Manual LP-SCR system: Change Tier mode Fig 7-5 Select: Prepare Tier III - 375 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 376: Select: Tier Iii

    AA00-9270-00AAA-100B-A Operation Manual LP-SCR system: Change Tier mode Fig 7-6 Select: Tier III - 376 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 377: Select: Tier Ii

    AA00-9270-00AAA-100B-A Operation Manual LP-SCR system: Change Tier mode Fig 7-7 Select: Tier II NOTE: If any major failure occurs or if the emergency bypass switch is operated, the LP-SCR will change back to Tier II mode. - 377 - Issue 001 2021-01 Winterthur Gas &...
  • Page 378 • Occurance of Surging WARNING If 2 or more cylinders are misfiring, Contact WinGD immediately. WARNING Running the engine under special running conditions for more than 2-5 days can damage the engine. If the engine is run under special running conditions for more than that, contact the engine builder to obtain advice.
  • Page 379 NOTE: For procedures B, D and E, always contact WinGD for a case specific calculation of allowable ouput and possible barred speed range. A.) Cylinder cut out while the piston and exhaust valve are still working and the compression is still on: On the LDU, access the “Fuel Injection Adjust Page”.
  • Page 380 AA00-0000-00AAA-100A-A Operation Manual Special running condition: Cylinder cut out WARNING When operating in this manner, the engine speed must stay 55% of the maximum continuous rating speed. Additionally, the over-speed level of the engine must be lowered to 80% of the continuous rating speed. NOTE: During maneuvers, the engine speed can be raised for 10 minutes to 80% of the continuous rating speed.
  • Page 381 AA00-0000-00AAA-100A-A Operation Manual Special running condition: Cylinder cut out On the page, turn of the fuel injection for the corresponding cylinder Disconnect the electrical plugs for the fuel injectors of the corresponding cylinder On the LDU, on the exhaust valve control page, make sure there are no error indications shown Make sure that the exhaust valve is completely closed If the exhaust valve isn’t completely closed, disconnect the plug for the cylinder starting...

  • Page 382: Allowed Load During Cylinder Cut Out

    AA00-0000-00AAA-100A-A Operation Manual Special running condition: Cylinder cut out After 15 minutes of running, open the crankcase and check: • The bearings • The temporarily secured parts • The oil flow through bearings • The tightness of blanked-off openings After 60 minutes of running, open the crankcase and check: •...
  • Page 383 AA00-0000-00AAA-100A-A Operation Manual Special running condition: Cylinder cut out Page left intentionally blank - 383 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 384 AA00-0000-00AAB-100A-A Operation Manual Special running condition: Turbocharger cut out 7.23 Special running condition: Turbocharger cut out The engine is designed to run with all its turbochargers working. If a turbocharger stops working, it must be repaired as soon as possible. However, if it is impossible to repair the not working turbocharger, then the engine can still be run, even with 2 turbochargers not working.
  • Page 385 AA00-0000-00AAB-100A-A Operation Manual Special running condition: Turbocharger cut out Remove the compensator (1) between the compressor outlet and the scavenge air duct. Remove the expansion piece (2) for the air outlet of the turbocharger (F) If there is oil loss, plug the turbocharger Switch on the manual mode of the auxiliary blower Make sure you are within the load restriction Verify the maximum firing pressure...
  • Page 386 AA00-0000-00AAB-100A-A Operation Manual Special running condition: Turbocharger cut out Make sure you are within the load restriction Verify the maximum firing pressure The turbocharger has been cut out successfully. The engine is now running under a special running condition. D.) For engines with one turbocharger but without the exhaust bypass option: Stop the engine Open the cover (E) Lock the rotor of the faulty turbocharger (check your turbocharger manual for details)

  • Page 387: Turbocharger Cut Out Procedure: Illustration 1

    AA00-0000-00AAB-100A-A Operation Manual Special running condition: Turbocharger cut out Insert the blanking plate (T1, T2, T3, T4) according to your turbocharger manual Remove the compensator (1) between the compressor outlet and the scavenge air duct. Remove the expansion piece (2) for the air outlet of the turbocharger (F) Insert an orifice plate (3, 4) in the compressor outlet If there is oil loss, plug the turbocharger Switch on the manual mode of the auxiliary blower...

  • Page 388: Turbocharger Cut Out Procedure: Illustration 2

    AA00-0000-00AAB-100A-A Operation Manual Special running condition: Turbocharger cut out Fig 7-10 Turbocharger cut out procedure: Illustration 2 - 388 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 389: Turbocharger Cut Out Procedure: Illustration 3

    AA00-0000-00AAB-100A-A Operation Manual Special running condition: Turbocharger cut out Fig 7-11 Turbocharger cut out procedure: Illustration 3 - 389 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 390: Turbocharger Cut Out Procedure: Illustration 4

    AA00-0000-00AAB-100A-A Operation Manual Special running condition: Turbocharger cut out Fig 7-12 Turbocharger cut out procedure: Illustration 4 - 390 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 391: Turbocharger Cut Out Procedure: Illustration 5

    AA00-0000-00AAB-100A-A Operation Manual Special running condition: Turbocharger cut out Fig 7-13 Turbocharger cut out procedure: Illustration 5 NOTE: If during the one of the procedures mentioned in this chapter, an auxiliary blower becomes inoperative, it will automatically be cut out thanks to the built in non-return valve.
  • Page 392 AA00-0000-00AAB-100A-A Operation Manual Special running condition: Turbocharger cut out Page left intentionally blank - 392 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 393: Service During Operation

    Operation Manual 8 Service during operation Do an analysis of the system oil..........394 Do an analysis of the cylinder oil.

  • Page 394: Do An Analysis Of The System Oil

    AA00-0000-00AAA-371B-A Operation Manual Do an analysis of the system oil Do an analysis of the system oil Periodicity Description Working hours 3000 Working hours 6000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 395 Send the sample bottles in an applicable package to a laboratory for analysis. Do the procedures related to the results, refer to section [section not applicable for this engine] or to the document “Lubricants” on the WinGD website (https:// www.wingd.com/). CLOSE UP •...

  • Page 396: Do An Analysis Of The Cylinder Oil

    AA00-0000-00AAA-371A-A Operation Manual Do an analysis of the cylinder oil Do an analysis of the cylinder oil Periodicity Description Weeks Unscheduled After a fuel change Unscheduled After a cylinder oil change Unscheduled After a feed rate change Duration for performing preliminary requirements 2.0 man-hours Duration for performing the procedure 6.0 man-hours...

  • Page 397: Location Of Ball Valves - Dirty Oil Samples

    AA00-0000-00AAA-371A-A Operation Manual Do an analysis of the cylinder oil PROCEDURE Fig 8-1 Location of ball valves - dirty oil samples Closed Open Open Closed 00010 Do this procedure at a minimum of one time each week, and do it also in the conditions that follow: •...
  • Page 398 If the oil analyses are different, do the applicable recommended procedures related to the oil analysis from the laboratory, refer to section [section not applicable for this engine] or to the document “Lubricants” on the WinGD website (https:// www.wingd.com/). CLOSE UP •...
  • Page 399 AA00-0000-00AAA-371A-A Operation Manual Do an analysis of the cylinder oil Page left intentionally blank - 399 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 400: Feed Rate Adjustments - Running-In

    Running-in of new components - general Running-in of new components - general After an overhaul or an installation of new components of the piston running system, WinGD recommends a running-in procedure. This makes sure a correct film of cylinder oil on the piston running system is built.
  • Page 401 AA00-0000-00AAA-950B-A Operation Manual Running-in of new components - general Page left intentionally blank - 401 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 402: Running-In Of New Components

    AA00-0000-00AAA-950A-A Operation Manual Running-in of new components Running-in of new components Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 72.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description Specialization Engine crew Intermediate...
  • Page 403 Set the feed rate to 0.9 g/kWh. CLOSE UP • After 72 hours set the feed rate to the usual settings. Refer to the document “Lubricants” on the WinGD website (https://www.wingd.com/) or to section [section not applicable for this engine] - 403 - Issue 001 2021-01 Winterthur Gas &...

  • Page 404: Clean The Turbocharger During Operation

    AA00-6500-00AAA-200A-A Operation Manual Clean the turbocharger during operation Clean the turbocharger during operation Periodicity Description Weeks Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description Specialization...
  • Page 405 AA00-6500-00AAA-200A-A Operation Manual Clean the turbocharger during operation PROCEDURE Decrease the engine power to approximately 25 to 85%. Clean the compressor of the turbocharger, refer to the documentation of the manufacturer. Clean the turbine of the turbocharger, refer to the documentation of the manufacturer. CLOSE UP •...

  • Page 406: Clean The Scavenge Air Cooler During Operation

    AA00-6600-00AAA-200A-A Operation Manual Clean the scavenge air cooler during operation Clean the scavenge air cooler during operation Periodicity Description Weeks Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...

  • Page 407: Sac - Clean During Operation (Example)

    AA00-6600-00AAA-200A-A Operation Manual Clean the scavenge air cooler during operation PROCEDURE Fig 8-3 SAC - clean during operation (example) PLANT ENGINE 1381A 1371A Turbocharger 1361A 1361L Washing Plant SAC 1381L 1371L Scavenge Air Cooler Blower Blower 4075A 4071A 00520 - 407 - Issue 001 2021-01 Winterthur Gas &...
  • Page 408 AA00-6600-00AAA-200A-A Operation Manual Clean the scavenge air cooler during operation Decrease the engine power to approximately 45%. Make sure that compressed air is available at the shut-off valve (001, Figure 8-3) and fresh water is available at the shut-off valve (009). NOTE: The schematic diagram in Figure 8-3...
  • Page 409 AA00-6600-00AAA-200A-A Operation Manual Clean the scavenge air cooler during operation Page left intentionally blank - 409 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 410: Replace The Filter Element Of The Duplex Filter

    AA00-7200-00AAA-200A-A Operation Manual Replace the filter element of the duplex filter Replace the filter element of the duplex filter Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 411 AA00-7200-00AAA-200A-A Operation Manual Replace the filter element of the duplex filter PROCEDURE Change over to the clean filter chamber. Drain the clogged filter chamber. Remove the cover of the clogged filter chamber. Remove the filter element from the filter chamber. Clean the filter chamber.

  • Page 412: Do A Test Of The Exhaust Waste Valve

    AA00-8135-00AAA-320A-A Operation Manual Do a test of the exhaust waste valve Do a test of the exhaust waste valve Periodicity Description Weeks Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.2 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 413 AA00-8135-00AAA-320A-A Operation Manual Do a test of the exhaust waste valve PROCEDURE On the related control panel manually open the exhaust waste valve. Make sure that the exhaust waste gate is open. Close the exhaust waste valve. If the check is incorrect, find the cause and repair the fault. CLOSE UP •...
  • Page 414 AA00-8135-00AAA-320A-A Operation Manual Do a test of the exhaust waste valve Page left intentionally blank - 414 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 415 Operation Manual 9 Troubleshooting Troubleshooting - general data..........Malfunctions of systems and components.
  • Page 416 This list gives data about the related malfunction. Refer to the specified sequence during troubleshooting. For repair work refer to the related section of the Maintenance Manual. If you cannot repair the malfunction, speak to or send a message to WinGD. - 416 - Issue 001 2021-01 Winterthur Gas &...
  • Page 417 AA00-0000-00AAA-410B-A Operation Manual Troubleshooting - general data Page left intentionally blank - 417 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 418 AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components Malfunctions of systems and components 9.2.1 Table of malfunctions Malfunctions of the water systems (XX10NN to XX19NN) • Table 9-1 - Supply pressure of the cylinder cooling water is too low • Table 9-2 - Supply temperature of the cylinder cooling water is too low •...
  • Page 419 AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components • Table 9-29 - Leakage flow from the rail unit is too high • Table 9-30 - Fuel leakage flow from fuel rail items is too high (engine with FLV) • Table 9-31 - Fuel leakage flow from fuel rail items is too high (engine with ICU) •...
  • Page 420 AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components • Table 9-61 - Unwanted engine speed decrease • Table 9-62 - Unwanted engine stop - 420 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 421: Supply Pressure Of The Cylinder Cooling Water Is Too Low

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components 9.2.2 Malfunctions of the water systems (XX10NN to XX19NN) Tab 9-1 Supply pressure of the cylinder cooling water is too low Indication Possible cause Procedure PT1101A The cooling water supply system • Find the cause and repair the fault.

  • Page 422: Supply Temperature Of The Cooling Water To The Sac Is Too Low

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components Tab 9-5 Supply temperature of the cooling water to the SAC is too low Indication Possible cause Procedure TE1371A The cooling water supply system • Find the cause and repair the fault. is defective Tab 9-6 Temperature of the cooling water downstream of the SAC is too high...

  • Page 423: Lubricating Oil Supply Pressure At The Engine Inlet Is Too Low

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components 9.2.3 Malfunction of the oil systems (XX20NN to XX31NN) Tab 9-7 Lubricating oil supply pressure at the engine inlet is too low Indication Possible cause Procedure PT2001A The oil supply system is defective •...

  • Page 424: Servo Oil Leakage Flow From The Servo Oil Supply Unit Is Too High

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components Tab 9-12 Servo oil leakage flow from the servo oil supply unit is too high Indication Possible cause Procedure LS2055A The servo oil unit or a servo oil • Find the cause and repair the fault, refer to pipe is defective section 9.4 Examine the supply unit for...

  • Page 425: Piston Cooling Oil Temperature Downstream Of A Piston Is Too High

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components Tab 9-16 Piston cooling oil temperature downstream of a piston is too high Indication Possible cause Procedure TE2501-nnA This is a result of the malfunction • Do the repair shown there. Table 9-9 - Lubricating oil sup- ply temperature at the engine inlet is too high A piston ring is defective...

  • Page 426: Damper Oil Supply Pressure Upstream Of The Torsional Vibration Damper Is Too Low

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components Tab 9-21 Damper oil supply pressure upstream of the torsional vibration damper is too low Indication Possible cause Procedure PT2711A There is an incorrect setting of the • Set the throttle valve to the correct value. throttle valve An oil supply pipe is defective •...

  • Page 427: Fuel Supply Temperature Is Not In The Permitted Range

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components 9.2.4 Malfunction of the fuel system (XX34NN) Tab 9-25 Fuel supply temperature is not in the permitted range Indication Possible cause Procedure TE3411A The fuel supply system is defec- • Find the cause and repair the fault. tive Tab 9-26 Fuel supply pressure at the engine inlet is too low...

  • Page 428: Fuel Leakage Flow From Fuel Rail Items Is Too High (Engine With Icu)

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components NOTE: The leakage flow from the FLV is related to the viscosity of the used fuel. Tab 9-31 Fuel leakage flow from fuel rail items is too high (engine with ICU) Indication Possible cause Procedure LS3446-nnA...

  • Page 429: Gas Concentration In Piston Underside Is Too High

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components 9.2.5 Malfunctions of systems for DF engine (XX33NN to XX39NN) Tab 9-34 Gas concentration in piston underside is too high Indication Possible cause Procedure AE3315C There is a leakage in the gas sys- •...

  • Page 430: Exhaust Gas Temperature Downstream Of A Cylinder Is Too High

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components 9.2.6 Malfunctions of the exhaust gas system (XX37NN) Tab 9-37 Exhaust gas temperature downstream of a cylinder is too high Indication Possible cause Procedure TE3701-nnA The scavenge air flow is too low •...

  • Page 431: Exhaust Gas Temperature Downstream Of A Turbocharger Is Too High

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components Tab 9-40 Exhaust gas temperature downstream of a turbocharger is too high Indication Possible cause Procedure TE3731-nnA A turbocharger surges • As a temporary procedure, decrease the engine load. • If applicable, open the exhaust waste gate valve.

  • Page 432: Scavenge Air Temperature In The Receiver Is Too High

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components 9.2.7 Malfunction of the air systems (XX40NN to XX44NN) Tab 9-43 Scavenge air temperature in the receiver is too high Indication Possible cause Procedure TE4031-nnA This is a result of the malfunction •...

  • Page 433: Condensation Flow At A Water Separator Is Too High

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components Tab 9-47 Condensation flow at a water separator is too high Indication Possible cause Procedure LS4071-nnA The filter in the return pipe is clog- • Clean the filter. The opening in the return pipe is •...

  • Page 434: Pressure Of The Air Spring Air Supply Is Too Low

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components Tab 9-52 Pressure of the air spring air supply is too low Indication Possible cause Procedure PT4341A There is an incorrect setting of the • Set the control air supply to the correct val- control air supply There is an incorrect setting of the •...

  • Page 435: Temperature Of A Thrust Bearing Pad Is Too High

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components 9.2.8 Miscellaneous malfunctions (XX45NN to XX52NN) Tab 9-57 Temperature of a thrust bearing pad is too high Indication Possible cause Procedure TE4521A This is a result of the malfunction • Do the repair shown there. Table 9-7 - Lubricating oil sup- ply pressure at the engine inlet is too low...

  • Page 436: Power Supply To The Power Supply Box E85 Has A Failure

    AA00-0000-00AAA-410C-A Operation Manual Malfunctions of systems and components Tab 9-60 Power supply to the power supply box E85 has a failure Indication Possible cause Procedure XS5056A The power supply is set to OFF • Set to ON the power supply. •...
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  • Page 438: Examples Of Failure Messages

    AA00-0000-00AAC-410C-A Operation Manual Failures and defects of UNIC-flex components Failures and defects of UNIC-flex components Failures and defects of UNIC-flex components cause failure messages, which are transmitted to the alarm and monitoring system (AMS). 9.3.1 Failure messages The UNIC-flex engine control system (ECS) constantly does internal integrity checks and monitors the connected sensors.

  • Page 439: Special Failures

    Repair the faults, or temporarily repair defective cables with insulation tape. • If necessary, replace damaged items. If you cannot repair a fault, speak to or send a message to WinGD. - 439 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 440 AA00-0000-00AAA-311A-A Operation Manual Examine the supply unit for servo oil leakage Examine the supply unit for servo oil leakage Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...

  • Page 441: Example Of Inspection Point

    AA00-0000-00AAA-311A-A Operation Manual Examine the supply unit for servo oil leakage PROCEDURE Do a check of the level switch LS2055A for free flow. If necessary, clean the bore of the pipe of the level switch. Carefully do a check of the temperature of the oil leakage pipe of each servo oil pipe to find the leakage pipe that has an oil flow.
  • Page 442 AA00-0000-00AAA-311A-A Operation Manual Examine the supply unit for servo oil leakage If there is no oil flow from none of the leakage pipes, find (if applicable) the connecting pipe that has a leakage as follows: Carefully loosen the screw plug of the inspection point of the first connecting pipe a maximum of two turns.
  • Page 443 AA00-0000-00AAA-311A-A Operation Manual Examine the supply unit for servo oil leakage Page left intentionally blank - 443 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 444 AA00-0000-00AAA-311B-A Operation Manual Examine the supply unit for fuel leakage Examine the supply unit for fuel leakage Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...

  • Page 445: Supply Unit (Example) And Example Of Inspection Point

    AA00-0000-00AAA-311B-A Operation Manual Examine the supply unit for fuel leakage PROCEDURE Do a check of the level switch LS3426A (if applicable also LS3427A) for free flow. If necessary, clean the bore of the pipe of the level switch. Carefully do a check of the temperature of the fuel leakage pipe (002, Figure 9-2) of each fuel pump (001) to find the leakage pipe that has a fuel flow.
  • Page 446 AA00-0000-00AAA-311B-A Operation Manual Examine the supply unit for fuel leakage Step 4 again for the other inspection points. If the related HP fuel pipes are tight, a fuel pump is defective. Thus do an overhaul of the fuel pump, refer to the Maintenance Manual 5556-1. NOTE: If the defective HP fuel pipe cannot be replaced immediately (or the engine must continue to operate), the related fuel pump must be cut out.
  • Page 447 AA00-0000-00AAA-311B-A Operation Manual Examine the supply unit for fuel leakage Page left intentionally blank - 447 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 448 AA00-0000-00AAA-311D-A Operation Manual Examine the ICU or fuel pipes for fuel leakage Examine the ICU or fuel pipes for fuel leakage Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 449 AA00-0000-00AAA-311D-A Operation Manual Examine the ICU or fuel pipes for fuel leakage PROCEDURE Do a check of the level switch LS3446A (if applicable also LS3447A) for free flow. If necessary, clean the bore of the pipe of the level switch. Carefully do a check of the temperature of the fuel leakage pipe of each injection control unit (ICU) (009) to find the leakage pipe that has a fuel flow.
  • Page 450 AA00-0000-00AAA-311D-A Operation Manual Examine the ICU or fuel pipes for fuel leakage 4.4.7 Step 4.4.1 Step 4.4.6 again for the connecting pipe (007) with the valves (001) and (012). If none of the connecting pipes have a leakage, find the ICU that has a fuel flow more than usual (compared to the amount of leakage from the other ICU) as follows: Put an oil tray under the screw-in union of the fuel leakage pipe (007) to collect the usual fuel flow.
  • Page 451 AA00-0000-00AAA-311D-A Operation Manual Examine the ICU or fuel pipes for fuel leakage Page left intentionally blank - 451 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 452 AA00-0000-00AAA-311C-A Operation Manual Examine the FLV or fuel pipes for fuel leakage Examine the FLV or fuel pipes for fuel leakage Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...

  • Page 453: Leakage On Flv And Pipes (Example)

    AA00-0000-00AAA-311C-A Operation Manual Examine the FLV or fuel pipes for fuel leakage PROCEDURE Fig 9-3 Leakage on FLV and pipes (example) Legend HP fuel pipe to injection valve Fuel rail Screw Fuel leakage pipe Screw-in union Screw-in union Fuel leakage pipe Flow limiting valve (FLV) Do a check of the level switch LS3446A for free flow.
  • Page 454 AA00-0000-00AAA-311C-A Operation Manual Examine the FLV or fuel pipes for fuel leakage If none of the leakage pipes (004) have a leakage, find the FLV that has a fuel flow more than usual (compared to the amount of leakage from the other FLV) as follows: Put an oil tray under the screw-in union (007, Figure 9-3) of the fuel leakage pipe...
  • Page 455 AA00-0000-00AAA-311C-A Operation Manual Examine the FLV or fuel pipes for fuel leakage Page left intentionally blank - 455 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 456 AA00-0000-00AAA-311E-A Operation Manual Examine the rail unit for leakage Examine the rail unit for leakage Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 457 AA00-0000-00AAA-311E-A Operation Manual Examine the rail unit for leakage PROCEDURE Do a check of the level switch LS3444A (if applicable also LS3445A) for free flow. If necessary, clean the bore of the pipe of the level switch. Carefully look into the rail unit to find the cause of the leakage. NOTE: Possible causes can be a defective pipe to the exhaust valve, a defective flange or an other defective item.
  • Page 458 AA00-0000-00AAA-662B-A Operation Manual Temporary isolate a cylinder with cooling water leakage Temporary isolate a cylinder with cooling water leakage Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 459 AA00-0000-00AAA-662B-A Operation Manual Temporary isolate a cylinder with cooling water leakage PROCEDURE Isolate the defective cylinder from the cooling water system. Make sure that there is no air spring air pressure. Lock the exhaust valve in the open position as follows: Remove the damper from the top housing (001).
  • Page 460 AA00-6500-00AAA-662A-A Operation Manual Temporary isolate a defective turbocharger 9.10 Temporary isolate a defective turbocharger Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 4.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description Specialization...

  • Page 461: Not All Turbochargers Are Defective (Example)

    AA00-6500-00AAA-662A-A Operation Manual Temporary isolate a defective turbocharger PROCEDURE Stop the engine. If not all turbochargers are defective, isolate the defective turbocharger from the exhaust gas system and from the scavenge air system. NOTE: This step is only applicable for an engine with more than one turbocharger, and if one ore two turbochargers are serviceable.

  • Page 462: All Turbochargers Are Defective (Example)

    AA00-6500-00AAA-662A-A Operation Manual Temporary isolate a defective turbocharger If all turbochargers are defective, isolate the defective turbochargers from the scavenge air system. NOTE: This step is applicable for an engine with one, two, or three turbochargers, and none of the turbochargers are serviceable. Lock the rotor of the defective turbochargers (refer to the turbocharger manual).
  • Page 463 AA00-6500-00AAA-662A-A Operation Manual Temporary isolate a defective turbocharger Page left intentionally blank - 463 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 464 AA00-8135-00AAA-662A-A Operation Manual Temporary isolate the exhaust waste gate 9.11 Temporary isolate the exhaust waste gate Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 465 AA00-8135-00AAA-662A-A Operation Manual Temporary isolate the exhaust waste gate PROCEDURE - 465 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 466 AA00-8135-00AAA-662A-A Operation Manual Temporary isolate the exhaust waste gate Stop the engine. Loosen the screws of the flange but do not loosen one of the two middle screws. Turn the flange (008) to close the exhaust waste gate. Tighten the screws to attach the flange (008). Start the engine.
  • Page 467 AA00-8135-00AAA-662A-A Operation Manual Temporary isolate the exhaust waste gate Page left intentionally blank - 467 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 468 AA00-0000-00AAA-662A-A Operation Manual Temporary cut out a defective injection valve 9.12 Temporary cut out a defective injection valve Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 469 AA00-0000-00AAA-662A-A Operation Manual Temporary cut out a defective injection valve PROCEDURE Cut out the injection of the related cylinder. NOTE: If possible, the exhaust valve must always operate. For an engine with direct controlled injection valves, disconnect the electrical connection from the injection valve.
  • Page 470 AA00-0000-00AAA-662D-A Operation Manual Temporary cut out a defective exhaust valve drive 9.13 Temporary cut out a defective exhaust valve drive Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 471 AA00-0000-00AAA-662D-A Operation Manual Temporary cut out a defective exhaust valve drive PROCEDURE Cut out the defective cylinder from the injection, refer to section 9.12 Temporary cut out a defective injection valve. Disconnect the electrical connection to the related exhaust valve control unit (VCU). Repair the fault as soon as possible, refer to the Maintenance Manual.
  • Page 472 AA00-9270-00AAA-720C-A Operation Manual Temporary isolate the HP SCR system 9.14 Temporary isolate the HP SCR system Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 4.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...

  • Page 473: Scr System - Covers (Example For 1 Turbocharger)

    AA00-9270-00AAA-720C-A Operation Manual Temporary isolate the HP SCR system PROCEDURE Fig 9-6 SCR system - covers (example for 1 turbocharger) Legend Cover SCR outlet valve SCR inlet valve - 473 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 474: Scr System - Covers (Example For 2 Turbocharger)

    AA00-9270-00AAA-720C-A Operation Manual Temporary isolate the HP SCR system Fig 9-7 SCR system - covers (example for 2 turbocharger) Legend Cover SCR outlet valve SCR inlet valve Remove the pipe to the SCR system from the flange downstream of the valve V1. Install the Cover (001,...
  • Page 475 AA00-9270-00AAA-720C-A Operation Manual Temporary isolate the HP SCR system Page left intentionally blank - 475 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 476 AA00-9270-00AAA-520C-A Operation Manual Connect the HP SCR system after isolation 9.15 Connect the HP SCR system after isolation Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 4.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 477 AA00-9270-00AAA-520C-A Operation Manual Connect the HP SCR system after isolation PROCEDURE Fig 9-8 SCR system - covers (example for 1 turbocharger) Legend Cover SCR outlet valve SCR inlet valve - 477 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 478 AA00-9270-00AAA-520C-A Operation Manual Connect the HP SCR system after isolation Fig 9-9 SCR system - covers (example for 2 turbocharger) Legend Cover SCR outlet valve SCR inlet valve Remove the cover (001, Figure 9-8 Figure 9-9) from the flange downstream of the valve V1.
  • Page 479 AA00-9270-00AAA-520C-A Operation Manual Connect the HP SCR system after isolation Page left intentionally blank - 479 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 480 AA00-5556-00AAA-510B-A Operation Manual Disconnect the fuel pump 9.16 Disconnect the fuel pump Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description Specialization Engine crew...
  • Page 481 AA00-5556-00AAA-510B-A Operation Manual Disconnect the fuel pump PROCEDURE Release the pressure and drain the related HP fuel pipe. Remove the related HP fuel pipe (001) from the fuel pump (002). For the applicable procedure, refer to the Maintenance Manual. Install the flange (005) to the fuel pump (002). Install the flange (006) to the HP fuel pipe (007).
  • Page 482 AA00-5556-00AAA-730B-A Operation Manual Connect the fuel pump 9.17 Connect the fuel pump Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description Specialization Engine crew...
  • Page 483 AA00-5556-00AAA-730B-A Operation Manual Connect the fuel pump PROCEDURE Release the pressure and drain the related HP fuel pipe. Remove the flange (005) from the fuel pump (002). Remove the flange (006) from the HP fuel pipe (007). Install the related HP fuel pipe (001) to the fuel pump (002). For the applicable procedure, refer to the Maintenance Manual.
  • Page 484 AA00-0000-00AAA-662C-A Operation Manual Isolate a defective engine at twin engine installation 9.18 Isolate a defective engine at twin engine installation Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 485 AA00-0000-00AAA-662C-A Operation Manual Isolate a defective engine at twin engine installation PROCEDURE Engage the shaft locking device of the defective engine. Refer to the related documentation of the manufacturer. NOTE: This prevents the windmilling effect on the propeller of the defective engine (shaft movement), when you operate the other engine.
  • Page 486 AA00-0000-00AAA-662C-A Operation Manual Isolate a defective engine at twin engine installation Page left intentionally blank - 486 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.

  • Page 487: Technical Data

    Operation Manual 10 Technical data 10.1 Engine data............. 10.2 List of usual values and safeguard settings - general.

  • Page 488: General Data

    AA00-0000-00AAA-030A-A Operation Manual Engine data 10.1 Engine data The standard data of the X72 engine is given in Table 10-1 - General data. Tab 10-1 General data Item Value Unit 720 mm Cylinder bore 3086 mm Piston stroke Speed range 66 to 89 rpm 4.29 -...

  • Page 489: Rated Power

    AA00-0000-00AAA-030A-A Operation Manual Engine data Tab 10-2 Rated power Rating point Speed Power BSFC Mean piston speed [rpm] [kW/cyl.] [g/kWh] [m/s] [bar] 3610 8.64 20.5 3610 9.16 19.4 2700 8.64 15.4 2700 9.16 14.5 2840 6.79 20.5 2120 6.79 15.4 Fig 10-1 Operating range R1 R1+...
  • Page 490 AA00-0000-00AAA-030K-A Operation Manual List of usual values and safeguard settings - general 10.2 List of usual values and safeguard settings - general For each system of the engine the tables in the chapter that follows give the values for usual operation and the trigger values for safeguard settings.
  • Page 491 AA00-0000-00AAA-030K-A Operation Manual List of usual values and safeguard settings - general • Trigger value This list gives the value at which the related safeguard function starts. For the analysis elements (AE) of concentration: ○ max - maximum concentration For the level switches (LS) and flow switches (FS): ○...

  • Page 492: Function Code

    AA00-0000-00AAA-030K-A Operation Manual List of usual values and safeguard settings - general 10.2.2 Signal codes - identification An example of a signal code is shown in Figure 10-2. Fig 10-2 Signal codes PT 1012 C 00207 Legend Function code Running number Function group Applied system Tab 10-3...

  • Page 493: Function Group

    AA00-0000-00AAA-030K-A Operation Manual List of usual values and safeguard settings - general Tab 10-4 Function group Code Signal type System 10 to 19 Signals from the engine Cooling water 20 to 29 Signals from the engine System oil, cooling oil Signals from the engine Cylinder lubrication Signals from the engine...

  • Page 494: Fuel System

    AA00-0000-00AAA-033B-A Operation Manual List of usual values and safeguard settings 10.3 List of usual values and safeguard settings On the pages that follow you find the values for usual operation and the trigger values for safeguard settings as follows: • Table 10-6 - Cooling water systems (XX10NN to XX19NN) •...
  • Page 495 This value is applicable for stable operation condition. This value is applicable for transient operation condition. WinGD recommends a setpoint value of 25°C. The trigger value should be 21°C if you use the recommended setpoint value of 25°C. - 495 - Issue 001 2021-01 Winterthur Gas &...
  • Page 496 AA00-0000-00AAA-033B-A Operation Manual List of usual values and safeguard settings Tab 10-7 Oil systems (XX2NNN, part 1) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Lubricating oil supply - system side Main lubricating oil / pressure [bar] / engine 4.2 to 5 PT2001A...

  • Page 497: Oil Systems (Xx2Nnn, Part 2)

    AA00-0000-00AAA-033B-A Operation Manual List of usual values and safeguard settings Tab 10-8 Oil systems (XX2NNN, part 2) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Servo oil Servo oil / pressure [bar] / distributor pipe PT2041A ≤...
  • Page 498 AA00-0000-00AAA-033B-A Operation Manual List of usual values and safeguard settings Tab 10-9 Oil systems (XX2NNN, part 3 (turbocharger bearing oil)) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Bearing oil turbocharger ABB A100/200-L with internal oil TC bearing oil / pressure [bar] / inlet each...

  • Page 499: Oil Systems (Xx2Nnn, Part 4)

    AA00-0000-00AAA-033B-A Operation Manual List of usual values and safeguard settings Tab 10-10 Oil systems (XX2NNN, part 4) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Damper oil Damper oil / pressure [bar] / inlet torsional 2.8 to 5.0 PT2711A...
  • Page 500 AA00-0000-00AAA-033B-A Operation Manual List of usual values and safeguard settings Tab 10-11 Fuel system (XX34NN) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Fuel supply - system side Fuel (HFO) / viscosity [cSt] / engine inlet 13 to 17 ≥...
  • Page 501 AA00-0000-00AAA-033B-A Operation Manual List of usual values and safeguard settings Tab 10-12 Exhaust gas system (XX37NN) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Exhaust pipe / manifold Exhaust gas / temperature [°C] / outlet each TE3701-nnA ≥...

  • Page 502: Air Systems (Xx40Nn To Xx44Nn)

    AA00-0000-00AAA-033B-A Operation Manual List of usual values and safeguard settings Tab 10-13 Air systems (XX40NN to XX44NN) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Scavenge air receiver Scavenge air / temperature [°C] / outlet 28 to 55 TE4031-nnA...
  • Page 503 AA00-0000-00AAA-033B-A Operation Manual List of usual values and safeguard settings Tab 10-14 Miscellaneous items (XX45NN to XX52NN) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Thrust bearing Pad / temperature [°C] / thrust bearing 45 to 75 TE4521A...
  • Page 504 AA00-0000-00AAA-033B-A Operation Manual List of usual values and safeguard settings Some items are continuously monitored for correct function. If an item becomes defective, the AMS sends a message to the ship alarm system, refer to Table 10-15 - Failure messages. Tab 10-15 Failure messages Medium / location Signal number...
  • Page 505 Operation Manual 11 Operating media 11.1 General for operating media..........11.2 Compressed air.
  • Page 506 Lubricants • Water NOTE: On the WinGD website go to your engine type, then to “OPERATION & MAINTENANCE”, then to “FUEL LUBRICANTS WATER”. On the pages that follow the specifications are available for the operating media that follow: • Compressed air •...
  • Page 507 AA00-0000-00AAA-018M-A Operation Manual General for operating media Page left intentionally blank - 507 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 508 • Purity class 2-4-2 (ISO 8573-1). 11.2.2 Recommended procedures for compressed air WinGD recommends to regularly do the procedures that follow to prevent explosions: • Regularly drain the starting air bottles to remove condensation. • Regularly clean the starting air pipes to remove oil that can come from the air compressors.
  • Page 509 AA00-0000-00AAA-030E-A Operation Manual Compressed air Page left intentionally blank - 509 - Issue 001 2021-01 Winterthur Gas & Diesel Ltd.
  • Page 510 AA00-0000-00AAA-030D-A Operation Manual Scavenge air 11.3 Scavenge air The turbocharger compresses the air from the engine room or from outside for the scavenge air. The air must be as clean as possible to keep the wear of cylinder liner, piston rings, turbocharger compressor etc to a minimum.

  • Page 511: Schematic Diagrams

    Operation Manual 12 Schematic diagrams 12.1 Schematic diagrams - general..........- 511 - Issue 001 2021-01 Winterthur Gas &...

  • Page 512: Schematic Diagrams

    AA00-0000-00AAA-043I-A Operation Manual Schematic diagrams - general 12.1 Schematic diagrams - general NOTE: The diagrams below are part of the Engine-Builder Drawing-Set and are not included in this operation manual. The diagrams below can be referenced directly in the specific Engine-Builder Drawing-Set. Please contact your Engine-Builder, if you need the specific diagrams.

  • Page 513: Process Codes

    AA00-0000-00AAA-043I-A Operation Manual Schematic diagrams - general 12.1.1.3 System codes in the engine control diagram The system codes in the engine control diagram are as follows: • Code 10 - Fuel system • Code 20 - Oil system • Code 25 - Cylinder oil system •...

  • Page 514: Function Code

    AA00-0000-00AAA-043I-A Operation Manual Schematic diagrams - general Fig 12-3 Signal codes PT 1012 C 00207 Legend Function code Running number Function group Applied system Tab 12-1 Function code Code First position Second position Analysis Control Control Element Flow Gauge Hand Indication Power Level...

  • Page 515: Function Group

    AA00-0000-00AAA-043I-A Operation Manual Schematic diagrams - general Tab 12-2 Function group Code Signal type System 10 to 19 Signals from the engine Cooling water 20 to 29 Signals from the engine System oil, cooling oil Signals from the engine Cylinder lubrication Signals from the engine Fuel gas Signals from the engine...

  • Page 516: Color Codes And Symbols - Electric Connection Diagram

    AA00-0000-00AAA-043I-A Operation Manual Schematic diagrams - general 12.1.2 Electric connection diagram The electric connection diagram shows data about the bus routing connections (without cylinder related signals). You can find an overview of the used color codes and symbols in Figure 12-4.

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